JP2014031073A - Method for manufacturing molded ceiling for vehicle - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a molded ceiling for a vehicle for making a base material easy to be peeled from a skin material without using adhesive impermeable paper, in coating treatment of end edges of the molded ceiling.SOLUTION: A method for manufacturing a molded ceiling for a vehicle is constituted so as to peel only an end material of a base material 1 from a skin material 7 in a peeling layer 10 by preliminarily interposing the peeling layer 10 for making the base material 1 and the skin material 7 easy to be peeled from each other even after molding, between the base material 1 and the skin material 7, in coating processing of end edges of the molded ceiling 20 for the vehicle, in which the peeling layer 10 is made into a two-layer structure nonwoven fabric layer where thermal bond nonwoven fabric 11 and fiber webs of thermoplastic synthetic fiber on the thermal bond nonwoven fabric 11b, are laminated, needle punch nonwoven fabric 12 is formed by interlacing the fiber webs, and fiber-to-fiber bonding is performed between the thermal bond nonwoven fabric 11 and the needle punch nonwoven fabric 12, the thermal bond nonwoven fabric 11 is laminated on a side of the base material 1, and the needle punch nonwoven fabric 12 is laminated on a side of the skin material 7.

Description

  The present invention relates to a method for manufacturing a molded ceiling for a vehicle.

A molded ceiling for a vehicle is generally a fabric called a fabric, a cloth, a knit, etc., with a base material such as a fiber system, a corrugated board system, a urethane system, and a foamed olefin system formed on a molding die whose molding surface is formed into a required curved surface. It is manufactured by setting together with a skin material made of and heating and pressing.
Here, the molded ceiling may be formed with, for example, a sunroof opening. The edge of the base material generated by the opening for the sunroof is covered so that the edge is not directly exposed to the indoor side by winding the skin material. In covering processing of the edge of the molded ceiling, first, a base material is cut from the back side of the molded ceiling, and only the end material of the base material is peeled off from the skin material. Then, an adhesive is applied to the part where the end material of the base material is peeled off from the skin material, and the skin material is wound around the edge of the base material and bonded. The covering process for the edge of the molded ceiling is also performed on the peripheral edge of the molded ceiling (for example, Patent Document 1). However, the manufacturing method disclosed in Patent Document 1 requires a first pressing step for forming the base material and a second pressing step for depositing the skin material, which increases the number of steps. It was.

  Therefore, in Patent Document 2, a non-woven fabric made of a cotton-like polyester resin is used as a release agent layer between a base material and a skin material, cut into the release agent layer, a cut surface is formed, and an end side from the cut surface A technique is disclosed in which an upper part is peeled from a peeling surface, a lower part on an end side having a skin material is bent along a cut surface, and a covering process is performed on an edge of a molded ceiling. However, simply using a nonwoven fabric for the release agent layer, the adhesive between the base material and the skin material easily oozes into the release agent layer, and the adhesive is cured with the adhesive penetrating into the release agent layer. End up. Therefore, the adhesive force between the base material and the skin material becomes stronger than necessary, and it is often difficult to peel off only the end material of the base material from the skin material with the release agent layer. In addition, since the adhesive that has oozed out into the release agent layer does not penetrate uniformly, the molding surface of the molding ceiling may be molded so as to be undulated, which may impair the appearance quality.

Therefore, Patent Document 3 describes a technique in which a release layer formed by adhering non-adhesive paper to the nonwoven fabric layer is interposed between the base material and the skin material. The release layer is made by laminating PET resin fibers on one side of adhesive-impermeable paper and entwining the PET resin fibers by the spunlace method (water needle). Combining. The spunlace method is a method in which fibers are entangled by intermittently jetting jet water streams from a large number of nozzles onto the surface of the fibers.
If the technique disclosed in Patent Document 3 is used, adhesive-impermeable paper is interposed between the base material and the skin material, so that the adhesive is prevented from oozing into the skin material. Therefore, the covering treatment of the edge of the molded ceiling does not require removing the cured adhesive after peeling only the end material of the base material from the skin material, and the molded surface of the molded ceiling undulates in an uneven shape. Molding is also suppressed.

Japanese Patent Laid-Open No. 11-042661 JP 2003-236960 A Japanese Patent No. 4820599

  However, the nonwoven fabric entangled by the spunlace method has a large difference in elongation between the water flow feeding direction and the direction perpendicular to the feeding direction. That is, the elongation of the nonwoven fabric is smaller in the water flow feeding direction than in the direction perpendicular to the feeding direction. The difference in the elongation of the nonwoven fabric appears more prominently when the basis weight increases. Therefore, it is necessary to consider the direction of elongation of the nonwoven fabric in the covering treatment of the edge of the molded ceiling. In addition, since the fine paper dust is scattered from the adhesive-impermeable paper when the spunlace method (water needle) is processed, it is necessary to process the release layer while preventing the paper dust from scattering. There was annoyance that there was. In view of the above, a release layer that replaces adhesive-impermeable paper is desired.

  The present invention was devised in view of the above points, and the problem to be solved by the present invention is that an adhesive-impermeable paper is not used in the coating treatment of the edge of the molded ceiling. An object of the present invention is to provide a method for manufacturing a molded ceiling for a vehicle that facilitates peeling of the material from the skin material.

In order to solve the above problems, the method for manufacturing a molded ceiling for a vehicle of the present invention takes the following means.
First, in the first invention, a molded ceiling is formed by setting a base material together with a skin material on a molding die whose molding surface is formed into a required curved surface, and heating and pressurizing the base material and the skin material. Thereafter, a cut is made in the base material from the back side of the molded ceiling, and only the end material of the base material is peeled off from the skin material, and an adhesive is applied to the part where the end material of the skin material is peeled off, and the skin material is applied to the base material. A method of manufacturing a molded ceiling for a vehicle, wherein the edge is covered with a skin material by being wound around and bonded to an edge of a base material, and the base is formed between the base material and the skin material after the molding. A peeling layer that facilitates peeling of the material and the skin material is interposed in advance, so that only the end material of the base material is peeled off from the skin material with the peeling layer, and the peeling layer is a thermal bond method. A thermal bond nonwoven fabric made of a thermoplastic synthetic fiber formed by A two-layer structure in which a fiber web of thermoplastic synthetic fibers is laminated on a printed nonwoven fabric, the fiber web is entangled to form a second nonwoven fabric, and the thermal bond nonwoven fabric and the second nonwoven fabric are interfiber bonded. It is set as the nonwoven fabric layer of a structure, The said thermal bond nonwoven fabric is laminated | stacked on the said base material side, The said 2nd nonwoven fabric is laminated | stacked on the said skin material side, It is characterized by the above-mentioned.

  According to the first aspect of the present invention, the thermal bond nonwoven fabric is formed by bonding fibers by thermally bonding a fiber web formed of short fibers through a heat roll and partially welding the fibers together. Is done. Therefore, in the thermal bond nonwoven fabric, a welded portion in which fibers are welded together and a fiber portion in which the fiber state is maintained are mixed. For this reason, the welded portion of the thermal bond nonwoven fabric prevents the adhesive at the time of molding the molding ceiling from becoming a wall and exuding to the skin material side. On the other hand, the fiber part of the thermal bond nonwoven fabric is separated by the fiber part being pulled and separated by the force of peeling off the end material of the base material from the skin material. Therefore, it is possible to easily peel off only the end material of the base material from the skin material. From the above, the covering treatment of the edge of the molded ceiling removes the cured adhesive after peeling the base material from the skin material without using an adhesive-impermeable paper for peeling the base material and the skin. There is no need, and the molding surface of the molding ceiling is not molded so as to corrugate. That is, it is possible to provide a method for manufacturing a molded ceiling for a vehicle that makes it easy to peel the base material from the skin material without using an adhesive-impermeable paper in the covering treatment of the edge of the molded ceiling.

  Next, according to a second aspect of the present invention, in the method for manufacturing a molded ceiling for a vehicle according to the first aspect, the release layer is entangled with the fibrous web by a needle punch method to form a second nonwoven fabric, and the thermal bond nonwoven fabric. And the second nonwoven fabric are bonded to each other between the fibers.

  According to the second invention, the release layer is formed by laminating a thermoplastic synthetic fiber fiber web on the thermal bond nonwoven fabric, and the fiber web is entangled by the needle punch method to form the second nonwoven fabric. Between the nonwoven fabric and the second nonwoven fabric is bonded between the fibers. In the needle punch method, fibers are entangled by reciprocating a needle (needle) that moves up and down at high speed in the thickness direction of the fiber web while feeding the fiber web in a certain direction. The layer of the second nonwoven fabric entangled by the needle punch method is higher in sublimation than the layer of the thermal bond nonwoven fabric. Therefore, the adhesive at the time of shaping | molding of a shaping | molding ceiling stops at the layer of the 2nd nonwoven fabric with high sublimation even when passing a thermal bond nonwoven fabric. That is, it is possible to further suppress the adhesive from penetrating to the skin material and to suppress the molding surface of the molding ceiling from being undulated. Moreover, since the layer of a 2nd nonwoven fabric has high sublimation compared with the layer of a thermal bond nonwoven fabric, it can exhibit a sound absorption performance. The layer of the second nonwoven fabric has a property that it is difficult for the fibers to peel off. Therefore, when only the end material of the base material is peeled from the skin material, delamination of the thermal bond nonwoven fabric is promoted in preference to the second nonwoven fabric layer, and only the base material end material can be easily peeled off from the skin material. . Further, the second nonwoven fabric entangled by the needle punch has a small difference in elongation between the feeding direction and the direction orthogonal to the feeding direction. Therefore, it is reduced to consider the direction of elongation of the nonwoven fabric in the entrainment work of the skin material.

  Next, a third aspect of the present invention is the method for manufacturing a molded ceiling for a vehicle according to the first aspect or the second aspect, wherein the thermal bond nonwoven fabric is configured to have a relatively smaller basis weight than the second nonwoven fabric. It is characterized by.

  According to the third invention, since the thermal bond nonwoven fabric is configured to peel only the end material of the base material from the skin material, it is preferably smaller than the basis weight of the second nonwoven fabric.

  Next, 4th invention is the manufacturing method of the molded ceiling for vehicles in any one of 1st invention from 3rd invention, The said peeling layer is previously affixed on the back surface of a skin material, It is characterized by the above-mentioned. .

  According to the fourth aspect of the invention, the peel layer is previously attached to the back surface of the skin material, so that the productivity of the vehicle molded ceiling can be further improved.

  The present invention is a method for manufacturing a molded ceiling for a vehicle, which makes it easy to peel the base material from the skin material without using an adhesive-impermeable paper in the covering treatment of the edge of the molded ceiling, by taking the measures of the above inventions. Can be provided.

It is a longitudinal cross-sectional view of the base material and skin material of a molded ceiling for vehicles. It is the schematic of the frame lamination construction method which manufactures the skin material of the shaping | molding ceiling for vehicles. It is the expanded longitudinal cross-sectional view which showed the state which laminated | stacked the fiber web on the thermal bond nonwoven fabric among manufacture of the peeling layer of the molded ceiling for vehicles. It is the expanded longitudinal cross-sectional view which showed the state which shape | molds a thermal bond nonwoven fabric and a fiber web by a needle punch method among manufacture of the peeling layer of the shaping | molding ceiling for vehicles. It is an expansion longitudinal cross-sectional view of the peeling layer of the molded ceiling for vehicles. It is a longitudinal cross-sectional view of the shaping | molding die which shows the manufacturing method of the shaping | molding ceiling for vehicles. It is a perspective view of the molded ceiling for vehicles. It is a longitudinal cross-sectional view when notching the principal part of the molded ceiling for vehicles. It is a longitudinal cross-sectional view when the end material of the principal part of the molded ceiling for vehicles is peeled off. It is a longitudinal cross-sectional view of the principal part of the molded ceiling for vehicles.

Embodiment 1 for carrying out the present invention will be described below with reference to FIGS.
The vehicle has a roof panel made of steel plate as a roof, and a molded ceiling 20 for the vehicle is mounted on the vehicle interior side of the roof panel.
As shown in FIG. 1, the molded ceiling 20 for a vehicle is formed by laminating a base material 1, a release layer 10, and a skin material 7, and heating and press-molding by a hot press to be integrated.
<About the base material 1>

The base material 1 is a part that is responsible for maintaining the shape of the molded ceiling 20 for the vehicle, ensuring rigidity, absorbing sound in the vehicle interior, heat insulation, and the like.
The substrate 1 is generally made of a thermoplastic synthetic fiber nonwoven fabric in which fiber reinforcing materials 3 and 4 coated with a thermosetting adhesive are laminated on both surfaces of the core material 2 and a non-breathable film 5 is interposed on the back surface thereof. A backing 6 is laminated.

  The core material 2 is provided in order to maintain the shape and ensure the rigidity, and may adopt an aspect having sound absorption and heat insulation in the vehicle interior. The core material 2 can be applied in various ways such as fiber, corrugated cardboard, urethane, and foamed olefin. In the first embodiment, a semi-rigid urethane foam made of urethane resin foam is selected as the core material 2.

The fiber reinforcing members 3 and 4 are provided for maintaining the shape and ensuring the rigidity of the entire molded ceiling 20 for a vehicle as shown in FIG. As shown in FIG. 1, the fiber reinforcing members 3 and 4 are laminated on both sides of the core member 2 on the vehicle interior side and the roof panel side. The fiber reinforcing material 4 is laminated on the roof panel side with respect to the core material 2, and the fiber reinforcing material 3 is laminated on the vehicle interior side with respect to the core material 2.
As shown in FIG. 1, the fiber reinforcements 3 and 4 are formed into a sheet shape by appropriately hardening chopped strands obtained by cutting glass fibers, which are inorganic fibers, to an appropriate length (for example, 50 mm to 100 mm length) with a binder. Has been. The glass fibers used here are not only those obtained by consolidating chopped strands as described above, but also those obtained by consolidating glass fibers with binders without being cut (continuous matte), glass fiber nonwoven fabrics, glass fiber papers, glass A fiber woven fabric may be used. In addition, the basis weight in the embodiment can be selected so as to meet the required strength and other various conditions. The fiber reinforcement is appropriately selected from inorganic fibers such as chopped strands, organic fibers such as jute (burlap), kenaf (marine), ramie, hemp (hemp), sisal hemp, bamboo and other natural fibers, etc. It may be in the form of a sheet or mat by a binder such as acrylic or needle processing.
In the first embodiment, a glass fiber mat is selected for the fiber reinforcements 3 and 4.

  The adhesive is a thermosetting resin made of an isocyanate resin. Since urethane foam having a semi-rigid layer is applied as the core material 2, it is preferable to select an isocyanate resin from the viewpoint that it is easily compatible with the urethane foam. The adhesive is not limited to the isocyanate resin, and is appropriately selected in relation to the core material 2 and the fiber reinforcing materials 3 and 4. The thermosetting resin is applied to the surface of the sheet-like glass fiber mat by a spray, a roll coater or the like. The coating amount is set to an amount that meets the required strength and other various conditions. A fiber reinforcing agent impregnated with a thermosetting resin may be used.

  As described above, the base material 1 according to the first embodiment has the fiber reinforcing materials 3 and 4 made of glass fiber mats by applying a thermosetting adhesive on both surfaces of the core material 2 made of semi-rigid urethane foam as shown in FIG. While laminating | stacking, the non-breathable film 5 was interposed in the back surface, and what laminated | stacked the backing material 6 which consists of PET resin fiber nonwoven fabrics was selected.

<About skin material 7>
The skin material 7 is a part that bears the design surface of the molded ceiling 20 for a vehicle. The skin material 7 is formed by laminating a surface layer 8 and a urethane foam sheet 9. The surface layer 8 can be variously applied to fabrics such as fabric, cloth, and knit, cloth members such as woven fabric, nonwoven fabric, and raised fabric, synthetic leather, artificial leather, and genuine leather. The urethane foam sheet 9 is laminated on the molded ceiling 20 for a vehicle by applying a soft layer made of a urethane resin foam to obtain a soft tactile sensation. There is also an aspect in which the urethane foam sheet 9 is not laminated.

<About Release Layer 10>
The release layer 10 is a thermosetting adhesive that makes it easy to peel off the base material 1 from the skin material 7 in the coating treatment of the edge of the molded ceiling 20 for vehicles described later, and is cured after the base material 1 is peeled off from the skin material 7. This is because the molded surface of the molded ceiling 20 for a vehicle is not molded so as to wave in an uneven shape.
As shown in an enlarged view in FIGS. 3 to 5, the release layer 10 includes a thermal bond nonwoven fabric 11 made of a thermoplastic synthetic fiber formed by a thermal bond method, and a thermoplastic synthetic fiber fiber on the thermal bond nonwoven fabric 11. The web 12a is laminated, the fiber web 12a is entangled by the needle punch method to form the needle punch nonwoven fabric 12 (second nonwoven fabric), and the thermal bond nonwoven fabric 11 and the needle punch nonwoven fabric 12 are interfiber bonded 2 It consists of a layer structure.

The thermal bond nonwoven fabric 11 is formed of a thermoplastic synthetic fiber by a thermal bond method as shown in FIGS. In the thermal bond method, a fiber web formed of thermoplastic synthetic short fibers (15 mm to 100 mm) is passed between hot rolls and thermocompression bonded, and the fibers are partially welded to bond the fibers together. It is a method of forming.
As the thermoplastic synthetic fiber, various synthetic fibers such as polyamide, polyester, and polyacrylonitrile can be applied. Note that polyethylene terephthalate is selected as the thermoplastic fiber of the thermal bond nonwoven fabric 11 in the first embodiment.
The thermoplastic synthetic resin fiber of the fiber web used for the thermal bond nonwoven fabric 11 is cut into a fiber length of 15 mm to 100 mm. If the thermoplastic synthetic resin fiber is less than 15 mm, the entanglement between the fibers decreases. On the other hand, when the thermoplastic synthetic resin fiber is longer than 100 mm, it becomes difficult to mix cotton, and it is difficult to uniformly mix the thermoplastic synthetic fiber with respect to the unit area, and it becomes difficult to form a uniform fiber mat.
The fiber web used for the thermal bond nonwoven fabric 11 can be formed by selecting any one of a dry method represented by a cross layer, an air lay, and the like, or a wet method represented by a papermaking method.
In the dry method (cross layer), thermoplastic synthetic resin fibers are cut into fiber lengths of 15 mm to 100 mm, mixed well with a fiber spreader (laminated cotton), and laminated with a card machine to obtain a fiber web having a predetermined basis weight.
In the dry method (air laid), thermoplastic synthetic resin fibers are cut into fiber lengths of 15 mm to 100 mm, and are well mixed (mixed cotton) with an air flow called air laid to form a fiber web having a predetermined basis weight.
In the wet method, a thermoplastic synthetic resin fiber is cut into a fiber length of 15 mm to 100 mm, dispersed in water, sprinkled with a net-like net or the like to form a fleece, and dried with a heater to obtain a fiber web.
The fiber web formed in either the dry method or the wet method is passed through between the hot rolls as described above and thermocompression bonded, and the fibers are partially welded to bond the fibers into a fiber mat. . Therefore, in the thermal bond nonwoven fabric 11, a welded portion where the fibers are welded and a fiber portion that maintains the fiber state are mixed.

As shown in FIG. 3, a fiber web 12 a of thermoplastic synthetic fiber is laminated on the thermal bond nonwoven fabric 11.
As the thermoplastic synthetic fiber of the fiber web 12a, various synthetic fibers such as polyamide, polyester and polyacrylonitrile can be applied. Note that polyethylene terephthalate is selected as the thermoplastic fiber of the fiber web 12a in the first embodiment. The thermoplastic synthetic resin fiber of the fiber web 12a is cut into a fiber length of 15 mm to 100 mm for the same reason as the thermal bond nonwoven fabric. The fiber web 12a is formed by selecting a dry method represented by a cross layer, an air lay, or the like, or a wet method represented by a papermaking method, as described above.
As shown in FIGS. 4 and 5, the release layer 10 interlaces the fiber web 12 a by the needle punch method to form the needle punch nonwoven fabric 12, and between the thermal bond nonwoven fabric 11 and the needle punch nonwoven fabric 12 between the fibers. Combined to form a two-layer nonwoven fabric layer. Specifically, the needle punch method is a needle 22 that moves up and down at high speed with respect to the thickness direction of the thermal bond nonwoven fabric 11 and the fiber web 12a while feeding a laminate in which the fiber web 12a is laminated on the thermal bond nonwoven fabric 11 in a certain direction. The fiber web 12a is entangled by reciprocating the needle) to form the needle punched nonwoven fabric 12, and the thermal bond nonwoven fabric 11 and the needle punched nonwoven fabric 12 are interfiber bonded to form a two-layered nonwoven fabric layer. As shown in FIG. 4, the needle 22 (needle) has a needle 22 (needle) reciprocated from the thermal bond nonwoven fabric 11 side and a needle 22 (needle) reciprocated from the fiber web 12a side. Thereby, the peeling layer 10 is formed by reciprocating the needle 22 (needle) from both surfaces of the laminate. In addition, the needle 22 (needle) can be applied in various ways, such as a mode of reciprocating only from the thermal bond nonwoven fabric 11 side or a mode of reciprocating only from the fiber web 12a side.

Here, the basis weight of the thermal bond nonwoven fabric 11 of the peeling layer 10 is a ^{10g / m 2 ~50g / m 2} . When the basis weight of the thermal bond nonwoven fabric 11 is less than 10 g / m ² , the thermosetting adhesive easily oozes out to the surface layer 8 side. If the basis weight of the thermal bond nonwoven fabric 11 is greater than 50 g / m ² , the thermal bond nonwoven fabric 11 is difficult to delaminate when the substrate 1 is peeled from the skin material 7. Basis weight of the thermal bond nonwoven fabric 11, more preferably in the range of ^{15g / m 2 ~35g / m 2} .

In contrast, the basis weight of the needle punched nonwoven fabric 12 is a ^{70g / m 2 ~150g / m 2} . When the basis weight of the needle punched nonwoven fabric 12 is less than 70 g / m ² , when the thermosetting adhesive oozes out to the surface layer 8 side, the needle punched nonwoven fabric 12 cannot be stopped by the needle punched nonwoven fabric 12, and the molding ceiling 20 for vehicles is molded. There exists a possibility that the surface may be shaped so as to be undulated.
If the basis weight of the needle punched nonwoven fabric 12 is larger than 150 g / m ² , the weight of the molded ceiling 20 for the vehicle increases, which is not preferable. Basis weight of the needle punched nonwoven fabric 12, more preferably in the range of ^{80g / m 2 ~130g / m 2} .

Therefore, the total basis weight of the release layer 10 becomes ^{80g / m 2 ~200g / m 2} .

<About molding of skin material 7 and release layer 10>
As the skin material 7 and the release layer 10 in the first embodiment, the surface layer 8 made of a fabric such as a fabric, the urethane foam sheet 9, and the release layer 10 manufactured by a frame laminating method were selected.
The skin material 7 and the release layer 10 are manufactured by the frame laminating method shown in FIG. 2, in which 8 is a surface layer made of a fabric such as a fabric wound in a roll shape, and 9 is a roll shape. The urethane foam sheet 10 is wound around the release layer 10 in a roll shape.
In this frame laminating method, one surface of the urethane foam sheet 9 is blown and melted by the flame of the gas burner 13, and the needle punched nonwoven fabric 12 side of the release layer 10 is overlapped there and passed between the rolls 14 and 15. The outer surface of the urethane foam sheet 9 is melted by the flame of 16 and melted, and the surface layer 8 made of cloth is overlapped and passed between the rolls 15 and 17, so that the skin material 7 having the cross-sectional structure shown in FIG. The layer 10 is wound into a roll.

<About the manufacture of the molded ceiling 20 for vehicles and the covering process of the edge of the molded ceiling 20 for vehicles>
Then, as shown in FIG. 6, the base material 1 is set together with the skin material 7 and the release layer 10 between the molds 18 and 19 whose molding surfaces are formed in a required curved surface, and heated and pressurized to thereby form the base material 1. The base material 1 and the skin material 7 are bonded together by melting and infiltrating a thermosetting adhesive between the base material 1 and the skin material 7. At this time, as for the peeling layer 10, the thermal bond nonwoven fabric 11 is laminated | stacked on the base material 1 side, and the needle punch nonwoven fabric 12 is laminated | stacked on the skin material 7 side. The thermal bond nonwoven fabric 11 suppresses the penetration of the thermosetting adhesive into the needle punched nonwoven fabric 12 during this heating and pressurization. As a result, the molded ceiling 20 for a vehicle having a required three-dimensional curved surface as shown in FIG. 7 is obtained. FIG. 7 is a perspective view of the molded ceiling 20 for vehicles from the base material 1 side, and 20a is a hill-like part formed so as to rise slightly to the base material 1 side to form a sunroof opening, 20b. , 20c shows a hill-like portion formed so as to rise slightly toward the base material 1 so that the sun visor can be accommodated on the lower surface (inside the room).

Next, as shown in FIG. 8, the hill-shaped portion 20 a of the vehicle molded ceiling 20 is cut with a cutter knife 21 from the base 1 side to form a necessary opening such as a sunroof in the base 1.
And only the end material 1a made by this cutting is peeled from the skin material 7 by delamination of the thermal bond nonwoven fabric 11 as shown in FIG.
Specifically, the thermosetting adhesive is inhibited from penetrating the needle punched nonwoven fabric 12 by the thermal bond nonwoven fabric 11. Further, the needle punched nonwoven fabric 12 is higher in sublimation than the thermal bond nonwoven fabric 11. Therefore, even if there is a thermosetting adhesive that has permeated the needle punched nonwoven fabric 12 side, the thermosetting adhesive stops in the needle punched nonwoven fabric 12 and does not penetrate into the urethane foam sheet 9. Further, the thermal bond nonwoven fabric 11 is easily separated because delamination occurs when the fiber portion of the thermal bond nonwoven fabric 11 is pulled and separated by the force of peeling the end material 1a of the substrate 1 from the skin material 7. Moreover, even if the thermal bond nonwoven fabric 11 does not delaminate, the thermal bond nonwoven fabric 11 and the needle punched nonwoven fabric 12 are separated. Thereby, the urethane foam sheet 9 is not strongly pulled and broken, and only the end material 1a can be easily detached. And the adhesive agent is apply | coated to this urethane foam sheet 9, and the edge of the base material 1 is wound around the edge of the base material 1 as shown in FIG. It can be covered with the material 7 and looks good.

In addition, by providing the thermal bond nonwoven fabric 11, there is no possibility that the thermosetting adhesive will ooze out into the urethane foam sheet 9, and the appearance can be finished beautifully. In addition, since the needle punched nonwoven fabric 12 is provided, the needle punched nonwoven fabric 12 functions as a sound absorbing layer, and the molded ceiling 20 for vehicles has excellent sound absorbing performance.
In this embodiment, the sunroof opening is described, but the peripheral edge of the vehicle molded ceiling 20 can be subjected to the same edge processing.

Thus, the vehicle molded ceiling 20 according to the present embodiment has the following operational effects.
The thermal bond nonwoven fabric 11 is formed by bonding fibers by thermally bonding a fiber web formed of short fibers through a hot roll and partially welding the fibers. Therefore, in the thermal bond nonwoven fabric 11, a welded portion where the fibers are welded and a fiber portion that maintains the fiber state are mixed. Therefore, the welded portion of the thermal bond nonwoven fabric 11 is prevented from becoming a wall and exuding to the skin material 7 side with respect to the adhesive at the time of molding the molded ceiling 20 for a vehicle. On the other hand, the fiber portion of the thermal bond nonwoven fabric 11 is separated by the fiber portion being pulled and separated by the force that peels off the end material 1 a of the base material 1 from the skin material 7. Therefore, it is possible to easily peel off only the end material 1 a of the base material 1 from the skin material 7. As described above, the coating treatment of the edge of the molded ceiling 20 for a vehicle is cured after the base material 1 is peeled off from the skin material 7 without using an adhesive non-permeable paper for peeling the base material 1 and the skin. There is no need to remove the adhesive, and the molding surface of the molded ceiling 20 for a vehicle is not molded so as to corrugate. That is, it is possible to provide a method for manufacturing a vehicle-formed ceiling 20 that makes it easy to peel the base material 1 from the skin material 7 without using adhesive-impermeable paper in the covering process of the edge of the vehicle-formed ceiling 20. it can.

  In addition, the release layer 10 is formed by laminating a thermoplastic synthetic fiber fiber web 12a on a thermal bond nonwoven fabric 11, and interlaces the fiber web 12a by a needle punch method to form a needle punch nonwoven fabric 12 (second nonwoven fabric). Between the thermal bond nonwoven fabric 11 and the needle punch nonwoven fabric 12, the fibers are bonded to each other. In the needle punch method, fibers are entangled by reciprocating a needle (needle) that moves up and down at high speed in the thickness direction of the fiber web while feeding the fiber web in a certain direction. The layer of the needle punched nonwoven fabric 12 entangled by the needle punch method is higher in sublimation than the layer of the thermal bond nonwoven fabric 11. Therefore, the adhesive at the time of molding the molded ceiling 20 for a vehicle stops on the needle punched nonwoven fabric 12 having high sublimation even when passing through the thermal bond nonwoven fabric 11. That is, it is possible to further suppress the adhesive from penetrating up to the skin material 7 and to suppress the molding surface of the molded ceiling 20 for the vehicle from being undulated in an uneven shape. Moreover, since the layer of the needle punched nonwoven fabric 12 is higher in sublimation than the layer of the thermal bond nonwoven fabric 11, it can exhibit sound absorbing performance. Moreover, the layer of the needle punched nonwoven fabric 12 has the property that it is difficult to peel between fibers. Therefore, when only the end material 1a of the base material 1 is peeled from the skin material 7, delamination of the thermal bond nonwoven fabric 11 is promoted in preference to the layer of the needle punched nonwoven fabric 12, and only the end material 1a of the base material 1 is covered with the skin material. 7 can be easily peeled off. Further, the needle punched nonwoven fabric 12 entangled by the needle punch has a small difference in elongation between the feed direction and the direction orthogonal to the feed direction. Therefore, it is reduced to consider the direction of elongation of the nonwoven fabric in the work of winding the skin material 7.

  Further, since the thermal bond nonwoven fabric 11 is configured to peel only the end material 1 a of the base material 1 from the skin material 7, the thermal bond nonwoven fabric 11 is preferably smaller than the basis weight of the needle punched nonwoven fabric 12.

  Moreover, the productivity of the molded ceiling 20 for vehicles can be further improved by having the peeling layer 10 affixed in advance on the back surface of the skin material 7.

  In addition, since the base material 1 is formed into a required curved surface by heating and pressurizing with a molding die and the skin material 7 is applied at the same time, the required steps can be reduced and the release layer 10 can be formed in advance. By interposing, the base material 1 and the skin material 7 are easily peeled off, so that the end material 1a of the base material 1 can be easily removed, and the edge processing can be easily performed. Can be improved.

  As mentioned above, although embodiment of this invention was described, the vehicle interior material of this invention is not limited to this embodiment, It can implement with other various forms.

DESCRIPTION OF SYMBOLS 1 Base material 1a End material 2 Core material 3 Fiber reinforcement material 4 Fiber reinforcement material 5 Air-impermeable film 6 Backing material 7 Outer material 8 Surface layer 9 Urethane foam sheet 10 Release layer 11 Thermal bond nonwoven fabric 12 Needle punch nonwoven fabric (2nd nonwoven fabric) )
12a Fiber web 13 Gas burner 14 Roll 15 Roll 16 Gas burner 17 Roll 18 Mold 19 Mold 20 Vehicle ceiling 20a Hill 20b Hill 20c Hill 21 Cutter knife 22 Needle

Claims (4)

After forming the molded ceiling by setting the base material together with the skin material on a molding die whose molding surface is formed into a required curved surface, and heating and pressurizing to bond the base material and the skin material, from the back side of the molding ceiling Cut the base material and peel off only the end material of the base material from the skin material, apply the adhesive to the peeled portion of the skin material, and wind the skin material around the edge of the base material. A method for producing a molded ceiling for a vehicle in which the edge is covered with the skin material by bonding,
Between the base material and the skin material, a peeling layer that makes it easy to peel off the base material and the skin material even after molding is interposed in advance, so that only the end material of the base material is covered by the peeling layer. It is configured to peel from the material,
The release layer is formed by laminating a thermal bond nonwoven fabric made of a thermoplastic synthetic fiber formed by a thermal bond method and a thermoplastic synthetic fiber fiber web on the thermal bond nonwoven fabric, and entwining the fiber web. And a non-woven fabric layer having a two-layer structure in which fibers are bonded between the thermal bond nonwoven fabric and the second nonwoven fabric, and the thermal bond nonwoven fabric is laminated on the substrate side, 2. A method for producing a molded ceiling for a vehicle, wherein two nonwoven fabrics are laminated on the skin material side. It is a manufacturing method of the molded ceiling for vehicles according to claim 1,
The molded ceiling for a vehicle, wherein the release layer is entangled with the fiber web by a needle punching method to form a second nonwoven fabric, and the thermal bond nonwoven fabric and the second nonwoven fabric are bonded between the fibers. Manufacturing method. It is a manufacturing method of the molded ceiling for vehicles according to claim 1 or 2,
The method for manufacturing a molded ceiling for a vehicle, wherein the thermal bond nonwoven fabric has a smaller basis weight than the second nonwoven fabric. A method for manufacturing a molded ceiling for a vehicle according to any one of claims 1 to 3,
A method for producing a molded ceiling for a vehicle, wherein the release layer is previously attached to the back surface of the skin material.

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