JP2016101832A - Molded ceiling for vehicle - Google Patents

Abstract

PROBLEM TO BE SOLVED: To enhance the rigidity of a side part without performing adhesion to a metal-made bracket by a post-process, and to facilitate recycling and disposal work, in a molded ceiling for a vehicle which is attached to the inside of a vehicle body of a vehicle body outer plate.SOLUTION: In a molded ceiling 10 for a vehicle, a fiber material 15 composed of a glass fiber or the like and a surface material 23 composed of a nonwoven fabric or the like are laminated on a single side of a base material 11 composed of an urethane foam, and a rear surface material 25 composed of a fiber material 17 which is composed of a glass fiber or the like and a nonwoven fabric or the like is laminated on the other side of the base material 11, and made to integrally adhere thereto. Reinforcing members 21 composed of urethane foams or the like are embedded into sides 10a, 10b of the molded ceiling 10 in a vehicle width direction along a fore-and-aft direction of the molded ceiling 10, and a thickness of the molded ceiling 10 is made larger than the other part in the embedded portions of the reinforcing members 21, thus enhancing rigidity.SELECTED DRAWING: Figure 2

Description

  The present invention relates to a molded ceiling for a vehicle in which a fiber material, a front surface material, and a back surface material are laminated on a base material made of a resin foam and are integrally bonded.

  Conventionally, a molded ceiling 60 as shown in FIG. 7 is used as a vehicle interior material. As a structure of a conventional molded ceiling 60, there is a structure in which a surface material 65 and a back material 67 are laminated on both sides of a resin foam 61 via glass fiber layers 62 and 63 and bonded and integrated as shown in FIG. . In addition, the surface material 67 is a surface that is the inside of the vehicle.

Further, when the molded ceiling 60 is inserted into the vehicle through the opening for the windshield or the rear glass during the assembly work to the vehicle, the molded ceiling 60 is distorted or bent at the side portions 60a and 60b of the molded ceiling, which causes an assembly failure. It was easy.
As a countermeasure, a metal or hard plastic bracket is bonded to the side portions 60a and 60b of the molded ceiling 60 in a later step to reinforce the side portions.
However, since an additional post-process for bonding the bracket is necessary, there is a problem that the manufacturing of the molded ceiling becomes complicated and the cost increases. Furthermore, when the metal bracket is bonded to the molded ceiling, it is necessary to separate the metal bracket at the time of recycling and disposal, and there is a problem that the work becomes troublesome.

JP 2007-331673 A JP 2002-337160 A

  The present invention has been made in view of the above points, and can form a vehicle-mounted ceiling that can increase the rigidity of the side portion without adhering a metal bracket in a subsequent process, and can be easily recycled and discarded. The purpose is to provide.

  The invention according to claim 1 is for a vehicle in which a fiber material and a surface material are laminated on one side of a base material made of a resin foam, and a fiber material and a back surface material are laminated on the other side of the base material so as to be integrally bonded. It is a molded ceiling, and a reinforcing member is embedded along the front-rear direction of the molded ceiling on a side portion of the molded ceiling, and the thickness of the molded ceiling is larger than that of the other part in the embedded portion of the reinforcing member. Features.

  According to a second aspect of the present invention, in the first aspect, the reinforcing member is provided on the back side of the base material, and a back surface side of the molded ceiling is raised at a portion where the reinforcing member is embedded.

  The invention of claim 3 is characterized in that, in claim 1 or 2, the resin foam of the base material and the reinforcing member are made of urethane foam, and the reinforcing member is laminated in direct contact with the base material. To do.

  The invention of claim 4 is characterized in that, in claim 3, the reinforcing member comprises a laminate of urethane foam and reinforcing fiber material.

  According to the invention of claim 1, by embedding the reinforcing member along the front-rear direction of the molded ceiling in the side part that is easily distorted or bent when the molded ceiling is assembled, the rigidity of the side part is increased, It is difficult to cause distortion and bending. Furthermore, the rigidity of the side portion can be increased by increasing the thickness of the side portion, and the rigidity of the side portion can be effectively increased by the synergistic effect of embedding the reinforcing member and increasing the thickness. This makes it difficult to cause distortion and bending of the part.

  According to the invention of claim 2, the back surface side of the molded ceiling is raised at the embedded portion of the reinforcing member, so that the influence of the shape due to the increase in the thickness of the embedded portion of the reinforcing member is affected by the surface on the vehicle interior side of the molded ceiling. It is possible not to occur on the side, and it is possible to prevent the restriction of the interior design of the molded ceiling and the reduction of the interior space.

  According to the invention of claim 3, since both the resin foam and the reinforcing member of the base material are made of urethane foam, it is easy to prepare the raw material, and the rigidity and peel strength by adhesion can be increased. .

  According to invention of Claim 4, since the said reinforcement member consists of lamination | stacking of a urethane foam and a reinforcement fiber material, the rigidity increase effect by a reinforcement member can further be heightened.

It is the perspective view which looked at the molded ceiling for vehicles of one Example of this invention from the back side. It is 2-2 sectional drawing of FIG. 1, and the enlarged view of the A section. It is sectional drawing of each member before a hot press at the time of manufacture of the molded ceiling for vehicles, and a hot press type | mold. It is sectional drawing of the hot press type | mold which shows the time of hot press. It is sectional drawing of the hot press type | mold which shows the time of taking out the molded article after hot press. It is sectional drawing which shows the side part vicinity of the molded ceiling for vehicles which concerns on another Example. It is the perspective view which looked at the conventional molded ceiling for vehicles from the back side. It is 8-8 sectional drawing of FIG.

  A molded ceiling 10 for a vehicle according to one embodiment shown in FIG. 1 is a ceiling member attached to the inside of a vehicle body outer plate of a vehicle. As shown in FIG. The materials 15 and 17, the reinforcing member 21, the front surface material 23, and the back surface material 25 are laminated at predetermined positions and are bonded and integrated. The molded ceiling 10 is curved at the side portions 10a and 10b corresponding to the side portion side of the vehicle, and is bent toward the inside of the vehicle.

  The base material 11 imparts heat insulation and sound absorption to the molded ceiling 10 and is made of a resin foam. As the resin foam, urethane foam, polyethylene foam, polypropylene foam, vinyl chloride foam, polystyrene foam and the like can be used. In particular, urethane foams such as semi-rigid urethane foam and flexible urethane foam are preferable from the viewpoint of heat insulation, sound absorption, and shock absorption. The urethane foam can be given a curved surface by hot press molding at 70 to 220 ° C. when the molded ceiling 10 is molded, and is suitable as the base material 11 of the molded ceiling 10. As hot press molding, after the molding material is heated to 70 to 220 ° C., a cold press method in which pressure is applied with a normal temperature press die, or a hot press method in which a normal temperature molding material is pressurized with a press die heated to 70 to 220 ° C. Any of these may be used.

  The base material 11 is impregnated and cured with a binder (adhesive) for bonding and integrating the fiber materials 15 and 17, the reinforcing member 21, the front surface material 23, and the back surface material 25. The rigidity of the molded ceiling 10 is increased by the impregnation and hardening of the binder.

  Examples of the binder include liquid isocyanates that are inexpensive and provide good adhesiveness. This liquid isocyanate is moisture-curing, that is, it reacts and cures by reaction with water (may be moisture in the air) in the presence of heat and catalyst, and functions as an adhesive by the curing. It can be used without any particular restrictions. For example, aromatic TDI (toluene diisocyanate), polymeric MDI (4,4′diphenylmethane diisocyanate), NDI (1,5-naphthalene diisocyanate), TODI (tolidine diisocyanate), PPDI (paraphenylene diisocyanate), XDI (xylylene diene) Isocyanate), TMXDI (tetramethylxylene diisocyanate), and their modified products. Preferably, polymeric MDI, modified TDI having various modifications such as urethane modification, allophanate modification, burette modification, carboimide / uretonimine modification, modified MDI and other modified TDI, and MDI, and mixtures thereof are suitable. ing.

  Among these, liquid isocyanate having a viscosity of 3 to 300 cp is more preferable because it is excellent in penetrability, coating property, and the like. Of these, polymeric MDI has particularly low vapor pressure and good affinity with glass fibers as inorganic fibers, and is suitable in terms of reactivity, adhesion, and workability. The type of these liquid isocyanates is appropriately selected and used depending on the adhesiveness, the rigidity, reactivity, and workability of the laminated product.

The fiber materials 15 and 17 arranged on both sides of the base material 11 are for increasing the rigidity of the molded ceiling 10 and may be made of carbon fiber, glass fiber or the like. In particular, glass fiber is inexpensive and has high rigidity, and is preferable. Glass fiber chops (those obtained by cutting roving glass) are layered, or glass fiber mats, glass fiber cloths, etc. It is suitable as the fiber materials 15 and 17. The weights of the fiber materials 15 and 17 are appropriately determined depending on the rigidity required for the molded ceiling 10.
Among these, a glass chopped strand mat that balances flexibility and tensile strength in both the length and width directions in a well-balanced manner is preferable for obtaining excellent moldability. That is, it is preferable that the glass chopped strands are appropriately oriented so that there is no anisotropy in tensile strength, and the glass chopped strand mat is thin and has a reduced weight. The basis weight is 50 to 150 g / m ² .

  The fiber materials 15 and 17 are cured by impregnating or adhering to the binder. As a result, the rigidity of the molded ceiling 10 can be further increased, and the adhesion and integration of the members can be improved. The same binder as the base material 11 and the binders of the fiber materials 15 and 17 are more preferable because they are economical in terms of raw material management and equipment.

  The reinforcing member 21 is provided in the front-rear direction (longitudinal direction) of the molded ceiling 10 with a predetermined width along the curved side portions 10 a and 10 b of the molded ceiling 10. In particular, a range that is within 300 mm from the edges on both sides and that reinforces the intermediate portion in the vehicle longitudinal direction and the upper side of the center pillar is preferable. In addition, the reinforcing member 21 is located between the fiber material 15 and the base material 11 in the side portions 10a and 10b and is in direct contact with the base material 11, so that the base material 11 and the reinforcing member 21 are integrated. It is preferable from the viewpoint of the increase in rigidity and rigidity.

  The reinforcing member 21 is not particularly limited as long as it has a rigidity increasing action such as a resin foam, a fiber material, a paper material such as cardboard. In particular, the reinforcing member 21 is preferably a resin foam that is the same as the resin foam constituting the substrate 11, and is preferably a urethane foam. If the reinforcing member 21 and the base material 11 are made of the same resin foam, it becomes easy to prepare raw materials for procurement, and the rigidity and peel strength due to adhesion can be increased. Examples of the urethane foam used as the reinforcing member 15 include soft urethane foam and semi-rigid urethane foam.

The reinforcing member 21 may be configured by stacking two types to further increase the rigidity. In this case, as shown in FIG. 6, it is preferable that the reinforcing member 21 is composed of a laminate of urethane foam 21a and fiber material 21b, and the urethane foam 21a is in contact with the base material 11 made of urethane foam. This is an example.
As an example of the dimensions of the reinforcing member 21, a width of 200 × length of about 300 to 600 mm is given. The thickness of the reinforcing member 21 varies depending on the material of the reinforcing member 21, but in the case of a resin foam, it is about 5 to 50 mm.
The reinforcing member 21 is impregnated with or adhered to the reinforcing member 21 and hardened, whereby the rigidity of the side portions 10a and 10b in the molded ceiling 10 is enhanced. The same binder as the binder impregnated in the base material 11 and the fiber materials 15 and 17 is more preferable in terms of raw material management, equipment, and the like.

  The surface material 23 is used to decorate or protect the surface of the molded ceiling 10 (the surface facing the vehicle interior). The surface material 23 is a non-woven fabric such as a polyester non-woven fabric, a woven fabric (knitted surface fabric), a fabric such as a polyester fiber, Plastic sheets such as thermoplastic elastomers) and PVC (polyvinyl chloride) are appropriately used.

  The said back surface material 25 is for protecting the back surface of the said molding ceiling 10, and consists of appropriate sheet materials, such as a nonwoven fabric and a plastic sheet.

  Further, one or both of the surface material 21 and the back surface material 25 may be one in which a plastic film is arranged or integrated on the inner surface side (side facing the base material 11). As the plastic film, the front surface material 21 and the back surface material 25 are securely bonded to the fiber materials 15 and 17, and the ventilation of the base material 11 is prevented to prevent the molded ceiling 10 from being soiled due to the air flow. Of these, a hot-melt film made of a material that melts and exhibits adhesiveness when heated is preferable. Examples of the hot melt film include EVA (ethylene vinyl acetate copolymer), EAA (copolymer of ethylene and acrylic acid), EMA (copolymer of ethylene and methyl acrylate), EMMA (ethylene and methyl methacrylate). Copolymer), EMAA (copolymer of ethylene and methacrylic acid) and a copolymer of polyolefin, or a thermoplastic resin having a melting point of 70 to 100 ° C., polypropylene, polyamide, PET (polyethylene terephthalate) And a polymer alloy with a thermoplastic resin having a melting point of 110 to 200 ° C.

  In the portion where the reinforcing member 21 is embedded (embedded portion), the thickness of the molded ceiling 10 is larger than the other portions, and the raised portions 10c, 10d are raised on the back side (vehicle body outer plate side) of the molded ceiling 10. Is formed. By increasing the thickness of the side portions 10a and 10b, the rigidity of the side portions 10a and 10b can be further increased. Further, by providing the raised portions 10 c and 10 d on the back side of the molded ceiling 10, the increase in thickness does not affect the shape on the surface material 23 side, and the vehicle interior design of the molded ceiling 10 is restricted. In addition, the vehicle interior space is not reduced.

  The molded ceiling 10 is manufactured by impregnating the base material 11, the fiber materials 15 and 17, the reinforcing member 21, etc. with the binder, and then, as shown in FIG. 3 and 4, as shown in FIG. 3 and FIG. 4, heat press with the lower die 51 and the upper die 55 for hot pressing to form the mold surface shape and cure the binder to bond the members together. Then, as shown in FIG. 5, the lower mold 51 and the upper mold 55 are opened and the molded ceiling 10 is taken out.

The lower mold 51 has a mold surface 52 for shaping the back surface of the molded ceiling 10 (the surface facing the vehicle body outer plate). The mold surface 52 is formed with raised portion forming recesses 53 and 54 at positions corresponding to the raised portions 10 c and 10 d of the molded ceiling 10.
The upper mold 55 has a mold surface 56 that shapes the surface of the molded ceiling 10 (the surface facing the interior of the vehicle).

Using the molding material as the next material, the above-described lower mold 51 and upper mold 55 were used, and the molded ceiling of the example was manufactured by hot pressing (hot pressing method, 120 ° C.).
・ Base material 11: Density 37 kg / m ³ , Asker C hardness 30 degrees, urethane foam with thickness 6 mm × width 1400 mm × length 2200 mm ・ Fiber material 15, 17: width 1400 mm × length 2200 mm, chopped strand glass fiber mat, Average fiber diameter 12 μm, basis weight: 100 g / m ²
-Reinforcing member 21: Density 40 kg / m ³ , Asker C hardness 30 degrees or less, urethane foam with thickness 30 mm × width 200 mm × length 1600 mm, elongation 12% or less, tensile strength 15 N / cm ² (JIS K6400-1: 2004, Dumbbell No. 2)
・ Surface material 23: Polyester non-woven fabric ・ Back surface material 25: Laminate of polypropylene hot melt film and polypropylene non-woven fabric ・ Binder: Crude ・ Methylene diphenyl diisocyanate

The binder is impregnated with 450 g / m ² in the base material 11 and 450 g / m ^{2 in} the reinforcing member 21, and is exuded from the base material 11 and the reinforcing member 21 by compression during hot pressing, and the fiber material. 15 and 17 were impregnated. The surface material 23 was adhered by a binder impregnated in the fiber material 15 and leached on the surface of the fiber material 15. The back material 25 was bonded by welding the hot melt film.

  The molded ceiling of the manufactured example was higher in the rigidity of the side portion than the conventional molded ceiling in which the reinforcing member 21 does not exist on the side portion, and it was difficult to cause the side portion to be distorted or bent. Furthermore, the molded ceiling according to the embodiment has a high side rigidity even if a metal bracket is not bonded in a subsequent process, and the manufacturing process can be simplified. In addition, the molded ceiling of the example does not have a metal bracket attached for the purpose of increasing rigidity, so there is no need to remove and separate the metal bracket during recycling or disposal, making recycling and disposal easier. Can be done. It is more preferable that the molded ceiling of the embodiment is used for a vehicle type such as a high roof or a one box whose side portion is deeply pierced in order to exhibit the effects of the invention.

  In the present embodiment, the reinforcing member is positioned on the vehicle body outer plate side with respect to the base material to form a raised portion that protrudes on the back surface side of the molded ceiling, but the present invention is not limited thereto, and as a modification, the reinforcing member is used as the base material. On the other hand, the raised portion can be formed by being positioned on the vehicle interior side (the surface facing the vehicle interior), and can be raised on the rear surface side of the molded ceiling. Further, a raised portion may be formed on the vehicle interior side (the side facing the vehicle interior). That is, in the modified example, the molded ceiling for a vehicle in which at least a resin foam and a fiber material are laminated and bonded with a binder, the reinforcing member positioned along the front-rear direction of the molded ceiling is disposed on the molded ceiling side. The reinforcing member is a molded ceiling for a vehicle that is embedded so as to protrude between a resin foam and a fiber material.

DESCRIPTION OF SYMBOLS 10 Molded ceiling 11 Base material 15, 17 Fiber material 21 Reinforcement member 23 Surface material 25 Back surface material

Claims (4)

A fiber material and a surface material are laminated on one side of a base material made of a resin foam, and the other side of the base material is a molded ceiling for a vehicle in which a fiber material and a back surface material are laminated and integrated.
Reinforcing member is embedded in the side part of the molded ceiling along the front-rear direction of the molded ceiling, and the thickness of the molded ceiling is larger than the other part in the embedded portion of the reinforcing member. ceiling.   The molded ceiling for vehicles according to claim 1, wherein the reinforcing member is provided on a back side of the base material, and a rear surface side of the molded ceiling is raised at a portion where the reinforcing member is embedded.   The molded ceiling for vehicles according to claim 1 or 2, wherein the resin foam of the base material and the reinforcing member are made of urethane foam, and the reinforcing member is laminated in direct contact with the base material.   The molded ceiling for vehicles according to claim 3, wherein the reinforcing member is a laminate of urethane foam and reinforcing fiber material.

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