JP2021535862A - 可変坪量を有するコア層及び複合品 - Google Patents
可変坪量を有するコア層及び複合品 Download PDFInfo
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- JP2021535862A JP2021535862A JP2021512562A JP2021512562A JP2021535862A JP 2021535862 A JP2021535862 A JP 2021535862A JP 2021512562 A JP2021512562 A JP 2021512562A JP 2021512562 A JP2021512562 A JP 2021512562A JP 2021535862 A JP2021535862 A JP 2021535862A
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- core layer
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- support element
- edge
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- Granted
Links
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Images
Classifications
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
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- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
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- D04H1/72—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged
- D04H1/732—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged by fluid current, e.g. air-lay
-
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-
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- B32B38/00—Ancillary operations in connection with laminating processes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B2260/02—Composition of the impregnated, bonded or embedded layer
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-
- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B2266/00—Composition of foam
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B2307/30—Properties of the layers or laminate having particular thermal properties
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- B32B2307/3065—Flame resistant or retardant, fire resistant or retardant
-
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B2605/00—Vehicles
- B32B2605/003—Interior finishings
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2605/00—Vehicles
- B32B2605/08—Cars
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
- B60R13/02—Internal Trim mouldings ; Internal Ledges; Wall liners for passenger compartments; Roof liners
- B60R2013/0287—Internal Trim mouldings ; Internal Ledges; Wall liners for passenger compartments; Roof liners integrating other functions or accessories
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R21/00—Arrangements or fittings on vehicles for protecting or preventing injuries to occupants or pedestrians in case of accidents or other traffic risks
- B60R21/02—Occupant safety arrangements or fittings, e.g. crash pads
- B60R21/16—Inflatable occupant restraints or confinements designed to inflate upon impact or impending impact, e.g. air bags
- B60R21/23—Inflatable members
- B60R21/231—Inflatable members characterised by their shape, construction or spatial configuration
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Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Textile Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Inorganic Chemistry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Dispersion Chemistry (AREA)
- General Chemical & Material Sciences (AREA)
- Laminated Bodies (AREA)
- Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Moulding By Coating Moulds (AREA)
Abstract
Description
本願は、開示全体が、すべての目的のために参照により本明細書に組み込まれる2018年9月4日に出願された米国仮出願第62/726,681号に対する優先権及びその利益を主張する。
LWRTコア層を、湿式堆積法でガラス繊維及びポリプロピレンを使用して製造した。LWRT材料のコアは、2つの表皮層で挟まれた。コア材料の坪量は、機械をまたがる方向に変化し、両方の端縁での目標坪量は約1000gsmであり、中心部では約1200gsmのより重い坪量であった。シートのレイアウトを図26に示す。製造後、シートは、加熱され、プレスで成形されて、例えば通常約2.5mmの所望の厚さを達成した。
実施例1の複合品の、例えば横方向などのボードの幅にわたる坪量が測定された。ボード全体にわたる横方向寸法は、約1524mmであった。各遷移ゾーンは、約100mmの横方向幅を有していた。「0」の距離は、複合品の左端であった。図27に示すように、坪量は、左端から遷移ゾーンまで増加し、次いで中心領域で横ばいになる。坪量は、次いで複合品の右端に近づくと再び減少する。
ボードの幅全体にわたるガラス含有量も測定された。図28は、結果を示すグラフである。「0」の距離は、複合品の左端であった。ガラス含有量は、端縁と比較して、ボードの中心領域に向かってほんのわずかに増加する。ガラス含有量が端縁でより低いのは、コア層全体にわたるガラス含有量のいずれの実質的な違いでもなく、2つの表皮層でのより低いガラス含有量に起因すると考えられる。
成形されたシートは、例えばASTM D790−17方法などのASTM D790の方法に従ってある特定の寸法に切断された。成形厚さは約2.5mmであった。
曲げピーク負荷と坪量の相関関係も、統計ツールを使用し調査された。Minitab(登録商標)18を使用して、多変数回帰分析を実施した。坪量、ガラス含有量、及び製造時の密度は、変数と見なされ(これらの変数は独立変数であることを証明することができる)、曲げピーク負荷は従属変数と見なされた。表I及び図31に示す出力に基づき、結果は、坪量と曲げピーク負荷の強い関係があることと一致していた。
表1
Claims (61)
- エアバッグの展開を可能にするように構成された複合材料を含む車両ヘッドライナーを製造する方法であって、
熱可塑性材料及び強化繊維の実質的に均質な混合物を含む分散液を成形支持要素の上に配置することと、
前記配置した発泡体を含む成形支持要素の全体に満たない表面に圧力を与えて、ウェブの異なる領域で可変坪量を含む多孔質ウェブを提供することと、
前記可変坪量を含む前記多孔質ウェブを乾燥させて、多孔質コア層の幅全体にわたって可変坪量を有する前記多孔質コア層を含む複合材料を提供することと
を含む、前記方法。 - 前記配置された分散液を含む前記成形支持要素の下側に負圧を与えることをさらに含む、請求項1に記載の方法。
- 前記配置された分散液を含む前記成形支持要素の中心領域に前記負圧を与えて、前記中心領域に前記多孔質コア層の端縁においてよりもより高い坪量を与えることをさらに含む、請求項1に記載の方法。
- 前記配置された分散液を含む前記成形支持要素の上側に正圧を与えることをさらに含む、請求項1に記載の方法。
- 前記配置された分散液を含む前記成形支持要素の中心領域に前記正圧を与えて、前記中心領域に前記多孔質コア層の端縁においてよりもより高い坪量を与えることをさらに含む、請求項4に記載の方法。
- 前記配置された分散液を含む前記成形支持要素の下側に負圧を与えること、及び前記配置された分散液を含む前記成形支持要素の上側に負圧を与えることをさらに含む、請求項1に記載の方法。
- 前記成形支持要素の前記下側に、前記成形支持要素の中心領域での前記成形支持要素の前記上側で与えられる前記負圧よりも大きい負圧を与えて、前記中心領域に、前記多孔質コア層の端縁においてよりもより高い坪量を与えることをさらに含む、請求項6に記載の方法。
- 前記成形支持要素の下側に負圧を与えること、及び前記成形支持要素の上側に正圧を与えることをさらに含む、請求項1に記載の方法。
- 前記成形支持要素の前記下側に与えられる前記負圧が、前記成形支持要素の前記下側全体にわたって実質的に均一になるように構成すること、及び前記上側の圧力を前記成形支持要素の中心領域においてより大きくなるように構成して、前記中心領域に、前記多孔質コア層の端縁においてよりもより高い坪量を与えることをさらに含む、請求項8に記載の方法。
- 前記成形支持要素の下側にマスクを配置すること、及び前記配置したマスクによって覆われていない前記ウェブの領域に負圧を与えることをさらに含む、請求項1に記載の方法。
- 前記多孔質コア層の第1の表面に第1の表皮を配置することをさらに含む、請求項1に記載の方法。
- 前記配置された第1の表皮が可変坪量を含む、請求項11に記載の方法。
- 前記多孔質層の第2の表面に第2の表皮を配置することをさらに含む、請求項11に記載の方法。
- 前記配置された第2の表皮が可変坪量を含む、請求項13に記載の方法。
- 第2の多孔質コア層を前記多孔質コア層に結合することをさらに含む、請求項1に記載の方法。
- 前記第2の多孔質コア層が、前記第2の多孔質コア層の異なる領域で実質的に均一な坪量を含む、請求項15に記載の方法。
- 前記第2の多孔質コア層が、前記第2の多孔質コア層の異なる領域で可変坪量を含む、請求項15に記載の方法。
- 第1の表皮を前記多孔質コア層の第1の表面に結合することをさらに含む、請求項15に記載の方法。
- 装飾層を前記配置された第2の表皮に結合することをさらに含む、請求項13に記載の方法。
- 前記圧力が前記成形支持要素に与えられている間に、前記分散液を前記成形支持層に配置することをさらに含む、請求項1に記載の方法。
- エアバッグの展開を可能にするように構成された複合材料を含む車両ヘッドライナーを製造する方法であって、
熱可塑性材料及び強化繊維の均質な混合物を含む分散液を成形支持要素の上に配置して、前記熱可塑性材料によってともに保持される前記強化繊維によって形成されたオープンセル構造のウェブを提供することと、
前記ウェブを乾燥させて多孔質コア層を提供することと、
可変坪量を含む第1の表皮を前記多孔質コア層の第1の表面に配置して、複合材料の異なる領域で可変坪量を有する前記複合材料を提供することと
を含む、前記方法。 - 前記第1の表皮の端縁での坪量よりも高い坪量を前記表皮の中心領域で含むように前記第1の表皮を構成することをさらに含む、請求項21に記載の方法。
- 可変坪量を含む第2の表皮を前記多孔質コア層の第2の表面に配置して、前記複合材料の異なる領域で前記可変坪量を有する前記複合材料を提供することを含む、請求項21に記載の前記方法。
- 前記第1の表皮及び前記第2の表皮を同じになるように構成することをさらに含む、請求項23に記載の方法。
- 前記第1の表皮及び前記第2の表皮の各々を、各表皮の中心領域において、各表皮の端縁での坪量よりもより高い坪量を含むように構成することをさらに含む、請求項24に記載の方法。
- 前記第1の表皮及び前記第2の表皮を異なるように構成することをさらに含む、請求項23に記載の方法。
- 前記配置された分散液に圧力を与えて、可変坪量を含むウェブを提供することをさらに含む、請求項21に記載の方法。
- 前記与える圧力を負圧として構成することをさらに含む、請求項21に記載の方法。
- 前記与える圧力を正圧として構成することをさらに含む、請求項28に記載の方法。
- 追加の強化繊維を前記配置されたウェブに適用して、ウェブに可変坪量を与えることをさらに含む、請求項21に記載の方法。
- 可塑性材料及び強化繊維から形成された多孔質コア層を含む複合材料を、車両エアバッグの展開中に端縁で前記複合材料の破損を促進するように構成することを含む方法であって、前記複合材料が可変坪量を含み、前記複合材料の中心領域での坪量が前記複合材料の端縁での坪量よりも大きく、前記車両エアバッグの展開中に前記端縁での前記複合材料の前記破損を促進する、前記方法。
- 前記多孔質コア層の各表面に配置された表皮層で前記複合材料を構成することをさらに含む、請求項31に記載の方法。
- 実質的に均一な坪量を含むように各表皮を構成することをさらに含む、請求項32に記載の方法。
- 可変坪量を含むように少なくとも1つの表皮を構成することをさらに含む、請求項32に記載の方法。
- 前記多孔質コア層の各端縁での坪量を、前記多孔質コア層の中心領域での平均坪量よりも少なくとも10%少なくなるように構成することをさらに含む、請求項31に記載の方法。
- 前記多孔質コア層の各端縁での坪量を、前記多孔質コア層の中心領域での平均坪量よりも少なくとも15%少なくなるように構成することをさらに含む、請求項31に記載の方法。
- 前記多孔質コア層の各端縁での坪量を、前記多孔質コア層の中心領域での平均坪量よりも少なくとも20%少なくなるように構成することをさらに含む、請求項31に記載の方法。
- 前記多孔質コア層の各端縁での坪量を、前記多孔質コア層の中心領域での平均坪量よりも少なくとも25%少なくなるように構成することをさらに含む、請求項31に記載の方法。
- 前記コア層の中心領域での坪量を、約500gsm〜約2000gsmになるように構成すること、前記多孔質コア層の各端縁での坪量を、前記コア層の前記中心領域での前記坪量より少なくとも10%少なくなるように構成すること、及び前記中心領域と各端縁との間の遷移領域の坪量を、傾斜坪量を含むように構成することをさらに含む、請求項31に記載の方法。
- 前記車両のサイドエアバッグの展開中に、前記端縁での前記複合材料の前記破損を促進するように前記複合材料を車両ヘッドライナーとして構成することをさらに含む、請求項31に記載の方法。
- ヘッドライナーキットであって、
熱可塑性材料及び強化繊維から形成され、車両エアバッグの展開中に端縁で前記車両ヘッドライナーの破損を促進するように構成された多孔質コア層を含む車両ヘッドライナーであって、前記車両ヘッドライナーが可変坪量を含み、前記車両ヘッドライナーの中心領域で坪量が、前記車両ヘッドライナーの前記端縁での坪量よりも大きく、前記車両エアバッグの展開中に前記端縁での前記車両ヘッドライナーの前記破損を促進する、前記ヘッドライナーと、
前記車両エアバッグを受け入れるように構成された車両空間に前記ヘッドライナーを設置するための説明書と
を備える、前記ヘッドライナーキット。 - 前記車両ヘッドライナーが、前記コア層の各側面に配置された表皮層をさらに含む、請求項41に記載のヘッドライナーキット。
- 前記車両ヘッドライナーが、前記表皮層の1つに配置された装飾層をさらに含む、請求項42に記載のヘッドライナーキット。
- 前記中心領域での横方向の前記坪量が、前記横方向の前記端縁での前記坪量よりも少なくとも20%大きい、請求項41に記載のヘッドライナーキット。
- 前記中心領域での前記坪量が、500gsm〜2000gsmであり、前記端縁での前記坪量が、前記中心領域での前記坪量よりも横方向で少なくとも10%少ない、請求項41に記載のヘッドライナーキット。
- 可変坪量を有する多孔質コア層を製造するためのシステムであって、
熱可塑性材料及び強化繊維の混合物を受け入れるように構成された成形支持要素と、
前記成形支持要素の第1の表面に流体結合して、前記成形支持要素の異なる領域に差圧を与えて、可変坪量を含むウェブを提供するように構成された圧力装置と、
前記ウェブを乾燥させて前記多孔質コア層を形成するように構成された乾燥機と
を備える、前記システム。 - 前記熱可塑性材料及び前記強化繊維を受け入れ、前記受け入れた熱可塑性材料及び前記強化繊維を混合して、前記熱可塑性材料及び前記強化繊維の実質的に均一な分散液を提供するように構成されたヘッドボックスをさらに備える、請求項46に記載のシステム。
- 前記成形支持要素を受け入れて、前記熱可塑性材料及び前記強化繊維の前記混合物から形成されたウェブを圧縮するように構成された1対のローラーをさらに備える、請求項47に記載のシステム。
- 前記成形支持要素の第2の表面で前記成形支持要素に流体結合するように構成された第2の圧力装置をさらに備え、前記第1の表面が、前記第2の表面の反対側にある、請求項46に記載のシステム。
- 前記圧力装置が、負圧を前記成形支持要素に与えるように構成され、前記第2の圧力装置が正圧を前記成形支持要素に提供するように構成される、請求項49に記載のシステム。
- 複合品であって、
熱可塑性材料によってともに保持された強化繊維によって形成されたオープンセル構造のウェブを含む多孔質コア層であって、前記多孔質コア層の幅全体にわたって可変坪量を含む前記多孔質コア層と、
前記多孔質コア層に結合された表皮層と
を含む、前記複合品。 - 前記多孔質コア層が、中心領域においてよりも横方向端縁においてより低い坪量を含む、請求項51に記載の複合品。
- 前記端縁の各々と前記中心領域との間に遷移ゾーンをさらに含み、前記遷移ゾーンの坪量が可変である、請求項52に記載の複合品。
- 前記遷移ゾーンが、0gsm/cmより大きく、最大30gsm/cmまでの坪量/距離の勾配を含む、請求項53に記載の複合品。
- 前記坪量/距離の勾配が、前記端縁から前記中心領域へ線形である、請求項54に記載の複合品。
- 前記強化繊維がガラス繊維を含む、請求項51に記載の複合品。
- 前記熱可塑性材料がポリオレフィン材料を含む、請求項56に記載の複合品。
- 前記多孔質コア層にロフト剤をさらに含む、請求項57に記載の複合品。
- 前記多孔質コア層に難燃剤をさらに含む、請求項58に記載の複合品。
- 前記端縁での平均坪量が、前記中心領域での平均坪量よりも少なくとも20%少ない、請求項51に記載の複合品。
- 請求項51〜60のいずれかに記載の前記複合品を備えるヘッドライナーを備える車両。
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