JP2022108745A - Heat insulation interior member, manufacturing method of heat insulation interior member and vehicular ceiling material having heat insulation interior member - Google Patents

Abstract

To provide a heat insulation interior member which can maintain the high heat insulation performance over a long period, is excellent in the productivity, handleability and reliability, is free from maintenance and is light-weight, and provide a manufacturing method of the heat insulation interior member and a vehicular ceiling material having the heat insulation interior member.SOLUTION: A heat insulation interior member 20 comprises: a first vacuum heat insulation material 27; a second vacuum heat insulation material; and a foamed body 23. The first vacuum heat insulation material 27 and the second vacuum heat insulation material are sealed in an outer bag in a decompressed manner such that a core material molded body molded with a core material including an inorganic powder body is surrounded by the outer bag. The foamed body is integrally laminated so as to cover the first vacuum heat insulation material 27 and the second vacuum heat insulation material.SELECTED DRAWING: Figure 3

Description

TECHNICAL FIELD The present invention relates to a heat-insulating interior member, a method for manufacturing the heat-insulating interior member, and a vehicle ceiling material provided with the heat-insulating interior member.

In the summer, the outside temperature of the vehicle is high and the temperature of the cabin rises due to strong sunlight, and in the winter, the outside temperature is low, so the heat in the cabin leaks to the outside and the temperature of the cabin drops. As a countermeasure against this, a heat insulating member is attached along the ceiling space of the vehicle from the passenger compartment side. As a heat insulating member, a vacuum heat insulating material covered with a foam (rigid polyurethane foam) is known. As a vacuum heat insulating material, there is known one in which a core material in which glass wool is flatly compressed into a sheet-like (plate-like) shape is enclosed in an outer bag under reduced pressure.

As a method of covering the vacuum insulation material with foam, the glass wool vacuum insulation material is placed inside the mold, the space between the mold and the vacuum insulation material is filled with the foam mixture, and the filled mixture is It is known to foam and cover vacuum insulation with foam. As a result, a flat heat insulating member in which the vacuum heat insulating material is covered with the foam is formed. This heat insulating member is attached to the ceiling space of the vehicle from the passenger compartment side (Patent Document 1).
However, when a vacuum insulation material with a glass wool core material is installed in the ceiling space of a vehicle, exposure to high temperatures may promote gas leakage, and gas convection within the core material may reduce the insulation performance. In addition, it is difficult to reduce the thickness of a vacuum heat insulating material having a glass wool core material, and weight reduction when attached to a vehicle is an issue. Further, the vacuum heat insulating material having a glass wool core material still has room for improvement in terms of conformability to curved surfaces for effective attachment to curved surfaces of vehicles.

In place of the glass wool core material, it is also possible to create a vacuum insulation material with a core material of inorganic powder bound with a binder, and to attach the insulation member covering the periphery with foam to the vehicle ceiling space from the passenger compartment side. It is known (patent document 2). If a core material containing inorganic powder is used, gas convection due to gas leakage is less likely to occur, and the internal airtightness of the vacuum heat insulating material can be easily maintained for a long period of time.

However, since the heat insulating member described in Patent Document 2 is also formed in a flat and thick film shape, when attaching the heat insulating member to the ceiling space of the vehicle, the curved surface shape (particularly, It is difficult to conform to a three-dimensional shape). Therefore, it takes a long time to attach the heat insulating member to the ceiling space of the vehicle, and there is still room for improvement in terms of productivity.
Furthermore, since the foam that covers the vacuum insulation material is exposed, there is a risk that the foam will be damaged when handling the vacuum insulation material and the insulation performance of the vacuum insulation material will be impaired. There is still room for improvement.

Japanese Patent No. 4661670 WO2014/087834

The present invention can follow curved surface shapes such as the ceiling space of a vehicle, can maintain high heat insulation performance over a long period of time, is excellent in productivity, handleability and reliability, does not require maintenance, and is a lightweight heat insulation interior member. Provided are a method for manufacturing a heat insulating interior member and a vehicle ceiling material provided with the heat insulating interior member.

The present invention has the following configurations.
[1] A vacuum heat insulating material in which a core material molded body having a core material containing inorganic powder is surrounded by an outer bag, and sealed under reduced pressure inside the outer bag, and the vacuum heat insulating material so as to cover the vacuum heat insulating material. and an integrally laminated foam, wherein the foam has a radius of curvature R of 10 mm or more when the foam is integrally laminated.
[2] The heat insulating interior member according to [1], wherein the thickness of the vacuum heat insulating material is 5 mm or less.
[3] The heat insulating interior member according to [1] or [2], wherein the core molded body has a density of 0.10 to 0.35 g/cm ³ .
[4] The number of vacuum insulation materials installed is n (n is an integer of 1 or more), the deployment area when the vacuum insulation materials are deployed in a horizontal direction to the installation surface of the vacuum insulation materials is Sn, and the heat insulation interior member When the allowable installation area Sx is the area obtained by subtracting the area of the opening from the developed area when developed in the horizontal direction with respect to the installation surface, the installation area ratio of the vacuum heat insulating material = (ΣSn/Sx) × 100. The heat insulating interior member according to any one of [1] to [3], which is 20% or more.
[5] The heat insulating interior member according to any one of [1] to [4], which further has sound absorption properties.
[6] The insulating interior member according to any one of [1] to [5], wherein the foam comprises rigid polyurethane foam.
[7] The insulating interior member according to any one of [1] to [5], wherein the foam comprises a semi-rigid polyurethane foam.
[8] The heat-insulating interior member according to any one of [1] to [7], comprising a skin material laminated integrally so as to cover the upper and lower surfaces of the foam.
[9] A step of molding a core material containing an inorganic powder to form a core molded body, a step of vacuum-sealing the core molded body inside an outer bag to obtain a vacuum heat insulating material, and the above-described The vacuum heat insulating material is formed by molding the vacuum heat insulating material according to the shape of the mounting portion to which the vacuum heat insulating material is to be mounted, and integrally molding a foam so as to cover the formed vacuum heat insulating material. A method for manufacturing a heat insulating interior member, comprising: a step of laminating on a heat insulating material.
[10] A vehicle ceiling material comprising the heat insulating interior member according to any one of [1] to [8].

INDUSTRIAL APPLICABILITY According to the heat-insulating interior member, the method for manufacturing the heat-insulating interior member, and the vehicle ceiling material provided with the heat-insulating interior member of the present invention, it can be applied to curved surfaces such as the ceiling space of a vehicle, and can maintain high heat insulation performance over a long period of time. , excellent productivity, ease of handling, reliability, and maintenance-free. Furthermore, as a result of being able to thin the heat insulating interior member itself, the weight of the heat insulating member can be reduced.

1 is a perspective view showing a vehicle provided with a heat insulating interior member according to an embodiment of the invention; FIG. FIG. 2 is a plan view schematically showing a state in which the heat insulating interior member of the embodiment is viewed from the roof side; 3 is a cross-sectional view along line III-III of FIG. 2; FIG. It is a perspective view which shows the 1st vacuum heat insulating material of embodiment. 4 is a cross-sectional view showing an enlarged V portion of FIG. 3; FIG. (a) is a cross-sectional view showing a step of placing a first skin material on a first stationary mold. (b) is a cross-sectional view showing a step of placing the first vacuum heat insulating material on the first skin material. (c) is a cross-sectional view showing a step of bending the first vacuum heat insulating material laminated on the first skin material. (a) is a cross-sectional view showing a step of laminating a foam on the first vacuum heat insulating material. (b) is a cross-sectional view showing a step of laminating a second skin material on the foam. (c) is a cross-sectional view showing a step of taking out the heat insulating interior member from the first fixed mold.

Next, embodiments of the present invention will be described based on the drawings. FR indicates the front of the vehicle, RR indicates the rear of the vehicle, RH indicates the right side of the vehicle, LH indicates the left side of the vehicle, and UP indicates the upper side of the vehicle, as seen from the vehicle occupants.
In addition, "-" indicating a numerical range means that the numerical values described before and after it are included as the lower limit and the upper limit.

As shown in FIG. 1 , a vehicle 10 is provided with a heat insulating interior member 20 at a mounting portion (mounting portion) of a roof 12 . In the embodiment, an example in which the vehicle ceiling material to be attached to the "roof 12" of the vehicle 10 is provided with the heat insulating interior member 20 will be described, but the attachment site is not limited to the roof 12. FIG. As another example, the floor of the vehicle 10 , the right front side door 13 , the left front side door, the right rear side door 14 , the left rear side door, the right rear fender 15 , the left rear fender, the bonnet 16 , and the inside of the rear lid 17 are vacuumed. Insulation can also be installed. Moreover, the vehicle 10 is not limited to a passenger car as shown in FIG. 1, and may be a vehicle such as a truck, an industrial vehicle, or a railroad.
A heat insulating interior member 20 is attached to the roof 12 of the vehicle 10 from the compartment 19 (see FIG. 3) side.

(insulation interior material)
As shown in FIGS. 2 and 3, the heat insulating interior member 20 includes a vacuum heat insulating portion 21, an adhesive layer 22, a foam 23, a first skin material (decorative member) 24, and a second skin material 25. , is equipped with
The heat-insulating interior member 20 is bent in a curved shape so that the entire area of the heat-insulating interior member 20 protrudes three-dimensionally upward from the vehicle in the vehicle width direction and the vehicle front-rear direction, for example, in accordance with the curved surface shape (shape) of the roof 12 . there is Further, the heat-insulating interior member 20 is, for example, bent into a curved shape with a smaller radius of curvature in the peripheral portion 20a than in other portions. In addition, the heat insulating interior member 20 has a projecting portion 20b that projects outward from the peripheral portion 20a.

The vacuum heat insulating part 21 includes a first vacuum heat insulating material 27 and a second vacuum heat insulating material 28 . The first vacuum heat insulating material 27 and the second vacuum heat insulating material 28 are primarily formed into a flat sheet shape (plate shape), and are further formed secondarily in accordance with the curved shape of the mounting portion 12x of the roof 12. .
In the embodiment, an example in which the vacuum heat insulating part 21 is composed of the first vacuum heat insulating material 27 and the second vacuum heat insulating material 28 will be described, but the shape and number of the vacuum heat insulating materials can be appropriately selected.

(vacuum insulation)
As shown in FIG. 4 , the first vacuum heat insulating material 27 includes a core molded body 31 and an outer bag 32 . The first vacuum heat insulating material 27 is a sheet-like (plate-like) heat insulating material that is surrounded by the core material molded body 31 that is housed in the outer bag 32, that is sealed inside the outer bag 32 under reduced pressure, and that is primarily formed. be.
The thickness T1 of the first vacuum heat insulating material 27 is substantially the same as that of the core molded body 31 .
The core molded body 31 contains inorganic powder. The core molded body 31 is formed by pressing (compression molding), molding, or the like a mixture of a core material containing inorganic powder and other components (described later) added as necessary. The core molded body 31 is usually molded into a plate-like sheet.

Examples of inorganic powder include fumed silica, which is an extremely fine powder. Specific examples of fumed silica include Aerosil 200 (specific surface area: 200 m ² /g, manufactured by Nippon Aerosil Co., Ltd.), Aerosil 300 (specific surface area: 300 m ² /g, manufactured by Nippon Aerosil Co., Ltd.), CAB-O-SIL M-. 5 (specific surface area 200 m ² /g, manufactured by Cabot Japan), CAB-O-SIL H-300 (specific surface area 300 m ² /g, manufactured by Cabot Japan), Rheoloseal QS30 (specific surface area 300 m ² /g, manufactured by Tokuyama) ).

Since fumed silica is an extremely fine powder, the specific surface area is usually used as an indicator of particle size.
The specific surface area of fumed silica is preferably 50 to 400 m ² /g, more preferably 100 to 350 m ² /g, particularly preferably 200 to 300 m ² /g. If the specific surface area of the fumed silica is at least the above lower limit, excellent heat insulation performance is likely to be obtained.
The specific surface area in the present invention is measured by the nitrogen adsorption method (BET method).
Since the first vacuum heat insulating material 27 uses extremely fine inorganic powder as a core material, gas convection due to gas leakage is unlikely to occur, and the heat insulating performance of the first vacuum heat insulating material 27 can be maintained for a long period of time.
As a result, the heat insulating interior member 20 can be maintained with high heat insulating performance over a long period of time, and the reliability is excellent, and maintenance can be made unnecessary.

The core molded body 31 may contain fibers. Examples of fibers include inorganic fibers and/or organic fibers shown below. Among them, inorganic fibers are preferable because they have little volatilization of gas components under vacuum, easily suppress deterioration of heat insulation performance due to a decrease in the degree of vacuum, and are excellent in heat resistance.
Examples of inorganic fibers include alumina fiber, mullite fiber, silica fiber, glass wool, glass fiber, rock wool, slag wool, silicon carbide fiber, carbon fiber, silica-alumina fiber, silica-alumina-magnesia fiber, silica-alumina. - Zirconia fiber, silica-magnesia-calcia fiber are mentioned. Among them, glass fiber, rock wool, or silica-magnesia-calcia fiber is preferable from the viewpoint of cost, safety, and the like.
Examples of organic fibers include nylon fibers, polyester fibers, vinylon fibers, wool fibers, and cotton fibers.
When the core molded body 31 contains fibers, the content of the fibers is preferably 2 to 30 parts by mass with respect to 100 parts by mass of the total mass of the inorganic powder and the fibers.

The outer bag 32 has airtightness and is capable of enclosing the core molded body 31 under reduced pressure. As the outer bag 32, for example, a bag made of a gas barrier film having excellent flexibility and high heat resistance can be used. As the gas barrier film, any known material used for vacuum insulation can be used without limitation.
Specifically, the outer bag 32 includes a first covering material 34 and a second covering material 35 . The first covering material 34 and the second covering material 35 are formed, for example, in a rectangular shape. The first outer covering material 34 and the second outer covering material 35 are thermally welded with a predetermined width dimension along three sides of the peripheral portion to form a welded portion 37 . As a result, the first outer covering material 34 and the second outer covering material 35 form a bag-like outer bag 32 with a three-sided seal. Note that the welded portion 37 may be bent for use.
The width dimension W of the welded portion 37 is preferably 5 to 20 mm. Within this range, a decrease in the degree of vacuum can be suppressed in long-term use.

The core molded body 31 is housed inside the outer bag 32, and in this state, the outer bag 32 and the core molded body 31 are placed in a vacuum chamber having a heat-sealing function. The inside of the outer bag 32 is depressurized, and the remaining one side of the opened bag is thermally welded and sealed. That is, the core molded body 31 is sealed inside the outer bag 32 under reduced pressure. As a result, the first vacuum heat insulating material 27 is flatly formed into, for example, a rectangular sheet shape (plate shape) in a plan view by the outer bag 32 and the core molded body 31 .

The degree of vacuum in the outer bag 32 of the first vacuum heat insulating material 27 is preferably 1×10 ³ Pa or less, and 5×10 ² Pa, in terms of excellent heat insulating performance and a long life of the first vacuum heat insulating material 27. The following is more preferable, and 1×10 ² Pa or less is even more preferable. The degree of vacuum in the outer bag 32 is preferably 1 Pa or higher, more preferably 3 Pa or higher, in order to facilitate decompression in the outer bag.

As shown in FIGS. 2, 3, and 5, the first vacuum heat insulating material 27 is aligned with the curved shape of the roof 12, for example, the entire area is three-dimensionally directed upwards in the vehicle width direction and the vehicle front-rear direction. It is bent into a curved shape so as to protrude from the bottom. Further, the first vacuum heat insulating material 27 is formed by bending the left side portion 27a and the right side portion 27b in a curved shape with a radius of curvature smaller than that of the other portions, for example, in the vehicle width direction.

For the first vacuum heat insulating material 27, for example, the density of the core material molded body 31 inside the outer bag 32 is preferably 0.10 to 0.35 g/cm ³ in terms of heat insulation and bending.
By setting the density of the core material molded body 31 to 0.10 g/cm ³ or more, the handling of the first vacuum heat insulating material 27 is facilitated, and powder is less likely to scatter during vacuum encapsulation. By setting the density of the core molded body 31 to 0.35 g/cm ³ or less, the heat insulating performance is excellent.
Thus, by setting the density of the core material molded body 31 to 0.10 to 0.35 g/cm ³ , the shape retention of the core material molded body 31 is ensured, and the heat insulating property of the first vacuum heat insulating material 27 is improved. can be achieved. The density of the core molded body 31 is more preferably 0.15 to 0.25 g/cm ³ .

In addition, the thickness T1 of the first vacuum heat insulating material 27 is preferably 5 mm or less, more preferably 2 to 4 mm, from the viewpoint of handleability and heat insulation of the heat insulating interior member 20 . Here, the thickness T1 refers to the thickness of a portion that does not include the bent portion when the welded portion 37 is used by being bent.
Since the core molded body 31 in the first vacuum heat insulating material 27 contains the inorganic powder, it is easy to mold into a thin shape. Therefore, the thickness T1 of the first vacuum heat insulating material 27 can be kept small. That is, the first vacuum heat insulating material 27 can be made lighter and thinner than when a conventional core material made by compressing glass wool or the like is used. As a result, the heat insulating interior member 20 can be made lightweight and thin, and the handleability of the heat insulating interior member 20 can be enhanced.

Further, when the core molded body 31 further contains fibers, the fibers function as reinforcing materials for the core molded body 31, so that the core molded body 31 does not need to contain a binder. Therefore, the heat insulating interior member 20 can be made lighter and thinner than when a conventional core material in which powder is coated with a binder is used.
According to the present invention, even when the thickness T1 of the first vacuum heat insulating material 27 is a thin film, specifically 5 mm or less, the thermal conductivity of the first vacuum heat insulating material 27 can be set to, for example, from 0.002 to 0.002. It can be kept small to 0.005 W/mK. Thereby, the heat insulating property of the first vacuum heat insulating material 27 can be ensured.
Further, by setting the thickness T1 of the first vacuum heat insulating material 27 to 2 to 4 mm, the heat insulating interior member 20 can be made lighter and thinner while the thermal conductivity of the first vacuum heat insulating material 27 is kept low.

A first skin material 24 (described later) is laminated on the back surface of the first vacuum heat insulating material 27 (that is, the second outer covering material 35) with an adhesive layer 22 interposed therebetween. As a constituent material of the adhesive layer 22, a liquid or foam adhesive is preferably used.
As the liquid adhesive, for example, an adhesive that can control the usable time of curing by air oxidation curing, moisture curing, temperature sensitivity, catalytic reaction, etc., that is, an adhesive on the back surface of the first vacuum heat insulating material 27 is applied. However, when the adhesive is positioned and placed on the first skin material 24, adhesive strength does not develop, and the adhesive has the property of starting to harden over time through processes such as exposure to air or moisture and heating. preferable. Examples of adhesives whose pot life can be controlled include room-temperature curing adhesives mainly composed of an anaerobic polymerizable monomer having a (meth)acrylic group and a radical polymerization initiator. Thermosetting resin adhesives such as epoxy adhesives and urethane adhesives can also be used. The two liquids of the above adhesive may be used together to control the pot life of curing.
As the foam adhesive, it is preferable to use a mixture of foams. By using the mixed solution of the foam as the foam adhesive, it is possible to absorb the strain caused by the difference in coefficient of linear expansion between the first vacuum heat insulating material 27 and the first skin material 24, and the deformation of the foam 23, which will be described later. In the molding process, the liquid mixture can flow between the first vacuum heat insulating material 27 and the first skin material 24 to form the adhesive layer 22 at the same time.

The second vacuum heat insulating material 28 has the same configuration as the first vacuum heat insulating material 27 except for the shape. Therefore, each constituent member of the first vacuum heat insulating material 27 is denoted by the same reference numeral as that of the first vacuum heat insulating material 27, and detailed description thereof is omitted.

(foam)
A foam 23 is integrally laminated so as to cover the first vacuum heat insulating material 27 and the second vacuum heat insulating material 28 (that is, the vacuum heat insulating portion 21). Hereinafter, in order to facilitate understanding of the configuration, the relationship between the first vacuum heat insulating material 27 and the foam 23 will be described, and the description of the relationship between the second vacuum heat insulating material 28 and the foam 23 will be omitted.

The foam 23 is formed so as to cover the upper surface of the first vacuum heat insulating material 27 (that is, the first outer covering material 34) and the peripheral edge 27c. The upper surface of the foam 23 is the surface facing the inner surface of the roof 12 . Examples of the foam 23 include rigid polyurethane foam and semi-rigid polyurethane foam.
Rigid polyurethane foams, for example, have open cells and are heat insulating and sound absorbing. Examples of rigid polyurethane foams include rigid polyurethane foams obtained by reacting a polyether polyol and a polyisocyanate compound in the presence of a blowing agent, a foam stabilizer and a catalyst. In addition to polyether polyols, polyhydric hydroxyl group-containing compounds such as polyester polyols can also be used.

The open cell ratio of the rigid polyurethane foam having open cells is preferably 60% or more, more preferably 70% or more, and particularly preferably 80% or more. If the open cell ratio is at least the lower limit, shrinkage of the rigid polyurethane foam is less likely to occur.
In addition, an open-cell rate is measured by the method based on JISK7138.

Moreover, the core density of the rigid polyurethane foam is preferably 20 kg/m ³ or more, for example, from the viewpoint of shrinkage deformation. By setting the core density of the rigid polyurethane foam to 20 kg/m ³ or more, shrinkage deformation of the rigid polyurethane foam can be made difficult to occur. The core density of rigid polyurethane foam is measured by a measuring method according to JIS K7222.

Alternatively, for example, closed-cell rigid polyurethane foam may be used instead of open-cell rigid polyurethane foam.
Furthermore, as the foam 23, a semi-rigid polyurethane foam can be used instead of the rigid polyurethane foam. Semi-rigid polyurethane foam is an intermediate material between flexible polyurethane foam and rigid polyurethane foam. A semi-rigid polyurethane foam has open cells and is preferable in terms of heat insulation and sound absorption. The semi-rigid polyurethane foam preferably has a core density of 20 kg/m ³ or more and an open cell ratio of 60% or more. If the core density and/or the open cell ratio of the semi-rigid polyurethane foam is at least the lower limit, the semi-rigid polyurethane foam is less likely to shrink.

The first vacuum heat insulating material 27 can be reinforced with the foam 23 by covering the upper surface (the first covering material 34 ) and the peripheral edge 27 c of the first vacuum heat insulating material 27 with the foam 23 . Thereby, the shape of the first vacuum heat insulating material 27 can be maintained by the foam 23, and the handleability of the heat insulating interior member 20 can be improved.
Further, by covering the upper surface (the first outer covering material 34) and the peripheral edge 27c of the first vacuum heat insulating material 27 with the foam 23, the heat insulating properties of the foam 23 are improved in addition to the heat insulating properties of the first vacuum heat insulating material 27. can be secured. As a result, the heat insulating property of the heat insulating interior member 20 can be further enhanced, and high heat insulating performance can be maintained over a long period of time.
Furthermore, by covering the upper surface (first outer covering material 34) of the first vacuum heat insulating material 27 and the peripheral edge 27c with the sound absorbing foam 23, the sound absorbing property can be secured as an additional function of the heat insulating interior member 20.

(skin material)
The first skin material 24 is laminated integrally with the back surface (the second covering material 35 ) of the first vacuum heat insulating material 27 with the adhesive layer 22 . In other words, the first skin material 24 is laminated integrally with the adhesive layer 22 so as to cover the surface of the adhesive layer 22 opposite to the attached portion 12x. That is, the first skin material 24 is a skin material that forms the back surface (backmost surface) of the heat insulating interior member 20 . As the first skin material 24, for example, a sheet base material made of a material having excellent flexibility and high heat resistance is decorated on the backmost side thereof. For example, the material of the seat base material includes fiber reinforced plastic (FRP), hard plastic or its foam, and the decorative member includes moldable knit, fabric, suede mixed synthetic leather, polyvinyl chloride leather, thermoplastic Examples include elastomer sheets. At this time, as the first skin material 24, a molded sheet in which the skin layer is integrated with the base material can also be used.

A second skin material 25 is integrally laminated on the surface 23a of the foam 23 on the attached portion side. That is, the second skin material 25 can serve as a skin that protects the surface (outermost surface) of the heat insulating interior member 20 . As the second skin material 25, for example, a sheet made of a thermoplastic resin that has excellent flexibility and can be pressure-formed can be used. In addition, when the second skin material 25 is laminated on the surface of the foam 23 of the heat insulating interior member 20, decoration of the outermost surface is not required.

When the outermost surface of the heat insulating interior member 20 is formed of the first skin material 24 and the outermost surface of the heat insulating interior member 20 is formed of the second skin material 25, the first vacuum heat insulating material 27 is formed of the first skin material 24. The foam 23 is covered with the second skin material 25 . Thereby, the first vacuum heat insulating material 27 is protected by the first skin material 24 and the foam 23 is protected by the second skin material 25 . Therefore, for example, damage to the first vacuum heat insulating material 27 can be suppressed by the first skin material 24 , and damage to the foam 23 can be suppressed by the second skin material 25 . As a result, the handleability of the heat insulating interior member 20 can be improved.
Moreover, the thickness T2 of the heat insulating interior member 20 is preferably 20 mm or less, more preferably 10 mm or less, from the viewpoint of handleability of the heat insulation interior member 20, for example.

Here, the heat insulating interior member 20 is integrally formed by laminating the first vacuum heat insulating material 27, the foam 23, the first skin material 24, and the second skin material 25. As shown in FIG. The radius of curvature R of the heat-insulating interior member 20 is set to 10 mm or more in order to correspond to the attached portion 12x and to prevent the outer bag 32 from being damaged. Further, the radius of curvature R of the heat insulating interior member 20 is more preferably 20 to 100 mm, and even more preferably 30 to 50 mm.
By setting the radius of curvature R of the heat insulating interior member 20 to 10 mm or more, for example, the heat insulating properties of the first vacuum heat insulating material 27 can be maintained for a long period of time, the reliability is excellent, and maintenance can be made unnecessary.

Further, by setting the radius of curvature R of the heat insulating interior member 20 to 10 mm or more, the heat insulating interior member 20 is bent into a curved shape with a small radius of curvature corresponding to the peripheral portion 12a of the roof 12, for example. Furthermore, the heat insulating interior member 20 is bent in a curved shape so that the entire area thereof protrudes three-dimensionally upward from the vehicle in the vehicle width direction and the vehicle front-rear direction, for example, in accordance with the curved surface shape of the roof 12 . .
Therefore, it is possible to correspond to various shapes of the mounting portion 12x such as the roof 12 to which the heat insulating interior member 20 is mounted. As a result, the heat insulating interior member 20 can be easily attached to various attachment portions 12x. As a result, it is possible to shorten the time required for installation work of the heat insulating interior member 20, and to increase productivity.

Here, the heat insulating interior member 20 includes an area between the first vacuum heat insulating material 27 and the second vacuum heat insulating material 28, an area around the first vacuum heat insulating material 27, and an area around the second vacuum heat insulating material 28. A foam 23 is provided in the . Thereby, the heat insulating interior member 20 is reinforced by the foam 23, and the handleability of the heat insulating interior member 20 can be improved.
Further, by reinforcing the heat-insulating interior member 20 with the foam 23, there is no need to separately prepare a reinforcing member, but if further strength is required, a reinforcing member may be provided on the entire surface or a part of it. .

In the heat insulating interior member 20, the first vacuum heat insulating material 27 and the second vacuum heat insulating material 28 are reinforced by the foam 23, and are bent to match the shape of the attached portion 12x. Since the first vacuum heat insulating material 27 and the second vacuum heat insulating material 28 can be formed so as to follow various shapes of the mounting portions 12x, construction can be performed without impairing the workability of conventional heat insulating members. As a result, it is possible to shorten the time required for installation work of the heat insulating interior member 20, and to increase productivity.

The relationship between the installation area (deployed area) of the vacuum heat insulating part 21 and the allowable installation area Sx of the heat insulating interior member will be described below.
It is assumed that the number of installed vacuum heat insulating materials is n (n is an integer equal to or greater than 1), and the spread area when each vacuum heat insulating material is spread out in a horizontal direction with respect to the installation surface of each vacuum heat insulating material is Sn. In the example of FIG. 2, the developed area of the first vacuum heat insulating material 27=S1, the developed area of the second vacuum heat insulating material 28=S2, and the developed area ΣSn of the vacuum heat insulating part 21=S1+S2. Also, let Sx be the installation allowable area of the heat-insulating interior member.

The deployment area S1 is the direction in which the first vacuum heat insulating material 27 is placed in a horizontal direction with respect to the installation surface of the first vacuum heat insulating material 27 (LH direction and RH direction in FIGS. 1, 2, 3 and 5, FR direction and RR direction (the same shall apply hereinafter).
The developed area S2 is the developed area when the second vacuum heat insulating material 28 is developed in a horizontal direction with respect to the installation surface of the second vacuum heat insulating material 28 .
The allowable installation area Sx is the area in which the vacuum insulation part 21 can be installed, and the contour shape of the heat insulation interior member 20 is expanded from the development area in the horizontal direction to the installation surface of the heat insulation interior member to the opening ( For example, it is the area excluding the unillustrated window portion and the development area of the room light installation portion 12b).

Using the developed area S1, the developed area S2, and the allowable installation area Sx, the installation area ratio is calculated by (ΣSn/Sx)×100.
The installation area ratio is preferably 20% or more, more preferably 20 to 90%. By setting the installation area ratio of the vacuum insulation part 21 to 20% or more, for example, the vacuum insulation part 21 (that is, the first vacuum insulation material 27) is placed above the occupants seated in the front seats (driver's seat, front passenger seat). can be arranged, and sufficient heat insulation for the occupants can be ensured. On the other hand, by setting the installation area ratio to 90% or less, for example, the vacuum heat insulating portion 21 can be provided at a certain distance from the end portion of the attached portion 12x. Therefore, for example, a space for arranging the foam 23 can be secured around the periphery of the vacuum heat insulating portion 21 , and the vacuum heat insulating portion 21 can be protected by the foam 23 . Thereby, the heat insulating property of the vacuum heat insulating portion 21 can be kept high for a long period of time.

For example, in the case of the embodiment shown in FIG. 2, with the heat insulating interior member 20 attached to the roof 12, for example, the first vacuum heat insulating material 27 is arranged above the front seats of the vehicle 10, and the second vacuum heat insulating material 28 are positioned above the rear seats of the vehicle 10 . The installation area ratio calculated in this case was [(S1+S2)/Sx]×100=about 48%.
Alternatively, depending on the type of vehicle 10 , it is conceivable to dispose the vacuum heat insulating portion 21 only above the front seats of the vehicle 10 . In that case, the installation area ratio of the vacuum heat insulating portion 21 is preferably 20% or more.

In this manner, the installation area, the number of installation units, and the installation location of the vacuum insulation unit 21 can be selected according to the required heat insulation performance, and the application can be expanded.

(Manufacturing method of heat insulating interior member)
Next, a method for manufacturing the heat insulating interior member 20 will be described with reference to FIGS. 6 and 7. FIG. Specifically, the first vacuum heat insulating material 27 and the second vacuum heat insulating material 28 formed into a flat sheet shape (plate shape) by primary molding are secondarily molded into a desired shape using a molding die (mold).
In the embodiment, the process of manufacturing the heat insulating interior member 20 in the first to fifth stages of the mold 40 will be described below as an example of the mold. In addition, the manufacturing method of the heat insulating interior member 20 is not limited to the manufacturing method shown below.
6 and 7, the first vacuum heat insulating material 27 of the vacuum heat insulating part 21 will be described as an example, and the description of the second vacuum heat insulating material 28 will be omitted.

In the first stage shown in FIG. 6( a ), the preformed first skin material 24 is placed along the molding surface 41 a of the first fixed mold 41 provided in the mold 40 .
Next, on the first stage shown in FIG. 6(b), the first vacuum heat insulating material 27 is placed on the first skin material 24 on the first stationary mold 41 while being positioned. At this time, it is preferable that the adhesive layer 22 is laminated on the rear surface of the first vacuum heat insulating material 27 facing the first skin material 24 . At this time, the first vacuum heat insulating material 27 can be placed on the first skin material 24 while being positioned by a robot or the like. In this state, the first stationary mold 41 is moved from the first stage to the second stage.

In the second stage shown in FIG. 6(c), the first vacuum insulation material 27 is press-molded to the first skin material 24 by clamping the first movable mold 42 provided in the molding die 40. As shown in FIG. That is, the first movable mold 42 presses the first vacuum heat insulating material 27 and the adhesive layer 22 toward the first skin material 24 on the first fixed mold 41 . At this time, the first vacuum heat insulating material 27 may be heated to a temperature of 80° C. or less and press-molded. The first vacuum heat insulating material 27 and the adhesive layer 22 are crimped along the first skin material 24 in a state where the first vacuum heat insulating material 27 and the adhesive layer 22 are familiar with the first skin material 24 . Therefore, the first vacuum heat insulating material 27 is integrally laminated on the first skin material 24 in a state in which the first vacuum heat insulating material 27 is adhered to the first skin material 24 with the adhesive layer 22 . At the same time, the first vacuum heat insulating material 27 is bent to match the curved shape of the inner surface of the first skin material 24 .
In this state, the first movable mold 42 is opened from the first fixed mold 41, and the first fixed mold 41 is moved from the second stage to the third stage.

In the third stage shown in FIG. 7( a ), the second movable mold 43 provided in the mold 40 is clamped to the first fixed mold 41 . A mixed liquid of the foam 23 is introduced into the cavity 44 formed between the first fixed mold 41 (specifically, the first vacuum insulation material 27) and the second movable mold 43 via runners 45 and gates 46. Fill as in A. The installation positions of the runners 45 and the gates 46 are not limited to the positions shown in FIG. 7(a).
The foam mixed liquid filled in the cavity 44 is foamed, and the foam 23 is integrated with the upper surface of the first vacuum heat insulating material 27 (that is, the first outer covering material 34) and the peripheral portion 24a of the first skin material 24. It is integrally formed by molding in the laminated state. Therefore, the foam 23 covers the upper surface (the first covering material 34) of the first vacuum heat insulating material 27 and the peripheral edge 27c.
In this state, the second movable mold 43 is opened from the first fixed mold 41, and the first fixed mold 41 is moved from the third stage to the fourth stage.

In the fourth stage shown in FIG. 7B, the third movable mold 48 provided in the molding die 40 is clamped to the first fixed mold 41 . A peripheral portion 25 a of the second skin material 25 softened by heating is attached to the third movable mold 48 . Therefore, by clamping the third movable mold 48 to the first fixed mold 41 , the second skin material 25 is placed on the foam 23 while being positioned. Air pressure is applied to the placed second skin material 25 toward the foam 23 as indicated by an arrow B, whereby the second skin material 25 is pressure-formed. As a result, the second skin material 25 is brought into close contact with the foam body 23 so that the second skin material 25 is integrally laminated on the upper surface of the foam body 23 . At this time, the peripheral portion 25a of the second skin material 25 and the peripheral portion 24a of the first skin material 24 are also integrally laminated.
The heat insulation interior member 20 is formed by integrally laminating the second skin material 25 on the upper surface of the foam 23 . In this state, the third movable mold 48 is opened from the first fixed mold 41, and the first fixed mold 41 is moved from the fourth stage to the fifth stage.

In the fifth stage shown in FIG. 7( c ), the heat insulating interior member 20 is released from the first fixed mold 41 and the heat insulating interior member 20 is taken out from the first fixed mold 41 . Next, of the peripheral portion 24a of the first skin material 24 and the peripheral portion 25a of the second skin material 25, the portion protruding outside from the cutting line 50 is trimmed. This completes the manufacturing process of the heat insulating interior member 20 .
By press-molding the first vacuum heat insulating material 27 on the first skin material 24 in this way, the first vacuum insulating material 27 is bent to form an integrally laminated state. Also, the foam 23 is integrally laminated on the first skin material 24 and the first vacuum heat insulating material 27 by molding. Furthermore, the second skin material 25 is integrally laminated on the foam 23 by pressure molding. That is, the first skin material 24, the first vacuum heat insulating material 27, the foam 23, and the second skin material 25 are integrally laminated in a short construction time by press molding, molding, air pressure molding, or the like. and increase productivity.

The technical scope of the present invention is not limited to the above-described embodiments, and various modifications can be made without departing from the gist of the present invention.
For example, in the above embodiment, an example in which the first vacuum heat insulating material 27 and the second vacuum heat insulating material 28 are collectively provided in the heat insulating interior member 20 as the vacuum heat insulating portion 21 has been described, but the present invention is not limited to this. As another example, the insulating interior member may be provided with one, or three or more vacuum insulation members.

Moreover, although the said embodiment demonstrated the example which shape|molds the foam 23 which covers the upper surface of the 1st vacuum heat insulating material 27 by molding, it does not restrict to this. As another example, the foam 23 can be molded by hot press molding.

DESCRIPTION OF SYMBOLS 10... Vehicle 12... Roof 12x... Mounting part 20... Thermal insulation interior member 23... Foam 24... First skin material 25... Second skin material 27... First vacuum heat insulating material 28... Second vacuum heat insulating material 31... Core material Molded body 32 Outer bag 40 Mold

Claims (10)

A vacuum heat insulating material in which a core material molded body having a core material containing inorganic powder is surrounded by an outer bag and sealed in the outer bag under reduced pressure;
a foam integrally laminated so as to cover the vacuum heat insulating material;
, wherein the foam has a radius of curvature R of 10 mm or more in a state in which the foam is integrally laminated. The thickness of the vacuum insulation material is 5 mm or less,
The heat insulating interior member according to claim 1. The core material molded body has a density of 0.10 to 0.35 g/cm ³ ,
The heat insulating interior member according to claim 1 or 2. The number of vacuum insulation materials installed is n (n is an integer of 1 or more),
Sn is the deployment area when the vacuum insulation material is deployed in a horizontal direction with respect to the installation surface,
When the allowable installation area Sx is the area obtained by subtracting the area of the opening from the developed area when the heat insulating interior member is deployed in the horizontal direction with respect to the installation surface,
The installation area ratio of the vacuum insulation material = (ΣSn/Sx) × 100 is 20% or more,
The heat insulating interior member according to any one of claims 1 to 3. It also has sound absorption properties,
The heat insulating interior member according to any one of claims 1 to 4. 6. An insulating interior member according to any preceding claim, wherein the foam comprises rigid polyurethane foam. 6. An insulating interior member according to any preceding claim, wherein the foam comprises a semi-rigid polyurethane foam. A skin material laminated integrally so as to cover the outermost surface and the outermost surface of the foam,
The heat insulating interior member according to any one of claims 1 to 7. A step of molding a core material containing inorganic powder to form a core material molded body;
a step of vacuum-sealing the core material compact inside an outer bag to obtain a vacuum heat insulating material;
A step of molding the vacuum heat insulating material with a mold so as to match the shape of the mounting portion to which the vacuum heat insulating material is to be mounted;
A step of laminating the foam on the vacuum insulation material by integrally molding a foam so as to cover the molded vacuum insulation material;
A method for manufacturing a heat insulating interior member, comprising: A vehicle ceiling material comprising the heat insulating interior member according to any one of claims 1 to 8.

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