JP2024025388A - Molding material for vehicle - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a molding material for vehicles capable of improving rigidity performance and vibration damping performance of a vehicle.

SOLUTION: Provided is a molding material 1 for vehicles arranged between a vehicle body panel P and a vehicle interior material. The molding material 1 for vehicles includes a core material 5 having a planar shape along the surface of a vehicle body panel, and fiber layers 6 and 7 laminated on both sides of the core material 5, and has a molded body solidified with a synthetic resin 13. A bonding layer 9 capable of bonding the surfaces in contact with the vehicle body panel P is laminated on an entire surface of the molded body on the vehicle body panel side. The molding material 1 for vehicles functions as a reinforcing member that supplements the surface rigidity of the vehicle body panel P by being surface-adhered to the vehicle body panel P by the bonding layer 9.

SELECTED DRAWING: Figure 2

COPYRIGHT: (C)2024,JPO&INPIT

Description

The present invention relates to a molded material for vehicles.

BACKGROUND ART Conventionally, structures are known in which various core materials are bonded to a ceiling panel or the like of a vehicle body for purposes such as vibration damping, sound insulation, and heat insulation. For example, there are structures in which an asphalt damping material is attached to a ceiling panel, and structures in which a corrugated cardboard core is attached to a ceiling panel with double-sided tape. These ceiling panels are covered with multiple steel members called reinforcements, ensuring the rigidity of the car body.

However, asphalt vibration damping materials are heavy, and the area where they can be attached to ceiling panels is limited. As a result, the vibration damping effect and surface rigidity of the vehicle body become limited. Furthermore, the corrugated cardboard core material is not shaped to match the shape of the ceiling panel, and is prone to problems such as distortion. Therefore, Patent Document 1 discloses a structure in which a foam molded body is disposed between a ceiling panel including a plurality of reinforcements and a base material. This foamed molded body has a shape that follows the undulations of the ceiling panel including the reinforcement, and is disposed so as to cover the reinforcement.

Patent No. 5819699

However, in a configuration in which a foam molded body is disposed between a vehicle body panel and a base material as described in Patent Document 1, although a vibration damping effect is exhibited, the effect of surface rigidity is considered to be small. Therefore, there is a need for a molded material for vehicles that can ensure both the surface rigidity and vibration damping performance of the vehicle body.

The present invention was devised in view of these points, and the problem to be solved by the present invention is to provide a molded material for a vehicle that can improve the rigidity performance and vibration damping performance of a vehicle body. There is a particular thing.

One feature of the vehicle molding material that solves the above problem is that the vehicle molding material is disposed between the vehicle body panel and the vehicle interior material, and the core material has a planar shape along the surface of the vehicle body panel. and a fiber layer laminated on both sides of the core material and solidified with a synthetic resin, and a molded body laminated on the entire surface of the molded body on the side of the vehicle body panel, joining the surfaces in contact with the vehicle body panel. By being surface-adhered to the vehicle body panel by the bonding layer, it functions as a reinforcing member that supplements the surface rigidity of the vehicle body panel.

One feature and advantage of the above structure is that the vehicle molding material has a structure in which fiber layers are laminated on both sides of a core material and solidified with synthetic resin, and it can be shaped into any shape to match the shape of the vehicle body panel. has been done. The vehicle molding material functions as a reinforcing member that supplements the surface rigidity of the vehicle body panel by being surface-adhered to the vehicle body panel using a bonding layer. Thereby, the strength of the vehicle body panel can be improved. Further, it is possible to suppress the occurrence of a gap between the vehicle molded material and the vehicle body panel, and it is possible to improve the vibration damping performance of the vehicle body. Furthermore, the vehicle molding material has a structure in which a core material and a fiber layer are laminated, and even when it is attached to a vehicle body panel over a wider area, an increase in weight can be suppressed. That is, the vehicle molding material can be attached to the entire surface of the vehicle body panel, and the effects of surface rigidity and vibration damping performance can be exerted over the entire surface of the vehicle body panel.

One feature of the vehicle molding material that solves the above problems is that the vehicle molding material is disposed between the vehicle body panel and the vehicle interior material, and is made of a fiber molded body solidified with a thermoplastic resin. The vehicle body panel has a core material having a planar shape along the surface of the vehicle body panel, and a bonding layer that is laminated on the entire surface of the molded body on the vehicle body panel side and is capable of bonding surfaces in contact with the vehicle body panel. By being surface-adhered to the surface by the bonding layer, it functions as a reinforcing member that supplements the surface rigidity of the vehicle body panel.

One feature and advantage of the above configuration is that the core material of the vehicle molded material is composed of a fiber molded body solidified with a thermoplastic resin, and is shaped into an arbitrary shape to match the shape of the vehicle body panel. The vehicle molding material functions as a reinforcing member that supplements the surface rigidity of the vehicle body panel by being surface-adhered to the vehicle body panel using a bonding layer. Thereby, the strength of the vehicle body panel can be improved. Further, it is possible to suppress the occurrence of a gap between the vehicle molding material and the vehicle body panel over the entire surface of the vehicle body panel, and it is possible to improve the vibration damping performance of the vehicle body. Furthermore, even when the fiber molded body constituting the core material is attached to a vehicle body panel over a wider area, an increase in weight can be suppressed. That is, the vehicle molding material can be attached to the entire surface of the vehicle body panel, and the effects of surface rigidity and vibration damping performance can be exerted over the entire surface of the vehicle body panel.

Regarding the above-mentioned molded material for a vehicle, the molded object includes the core material containing a urethane resin, and a first material containing glass fiber laminated on the surface of the core material on the vehicle body panel side via a thermosetting resin. and a second fiber layer containing glass fiber, which is laminated on the surface of the core material on the vehicle interior material side via a thermosetting resin, and the first fiber layer and The bonding layer may include a thermoplastic bonding film and a protective nonwoven fabric laminated on the bonding layer side surface of the bonding film.

One feature and advantage of the above structure is that the vehicle molding material has first and second fiber layers containing glass fibers laminated on both sides of a core material containing urethane resin, and these layers are made of thermosetting resin. They are joined together and shaped into one piece. Thereby, the shape of the molded material for a vehicle can be maintained and the rigidity can be further increased. Therefore, the vehicle molding material functions as a reinforcing member that supplements the surface rigidity of the vehicle body panel, and even if the vehicle body has few iron reinforcing members, the strength of the vehicle body panel can be ensured. That is, it is possible to reduce the number of iron reinforcing members corresponding to the strength supplemented by the vehicle molding material. Moreover, the molded material for a vehicle has a structure in which a core material whose specific gravity is lighter than that of an iron reinforcing member and a fiber layer are laminated. Therefore, when the vehicle molding material is disposed within the limited space between the vehicle body panel and the vehicle interior material, the weight at that location can be reduced. Therefore, in addition to improving the surface rigidity and vibration damping performance of the vehicle body panel, it is possible to reduce the weight of the vehicle body.

Regarding the molded material for a vehicle, the molded body may have a structure including the core material containing glass fiber and a thermoplastic resin, and the fiber layer made of a nonwoven fabric.

One feature and advantage of the above structure is that the vehicle molding material has fiber layers made of nonwoven fabric laminated on both sides of a core material containing glass fibers and a thermoplastic resin, and these are integrally shaped. By disposing this vehicle molding material, the vibration damping performance of the vehicle body panel can be further improved.

The above molded material for a vehicle may include a nonwoven fabric layer laminated on the surface of the second fiber layer on the vehicle interior material side.

One feature and advantage of the above configuration is that a nonwoven fabric layer is provided on the surface of the second fiber layer on the vehicle interior material side. Thereby, the sound absorption performance and sound insulation performance of the molded material for vehicles can be improved.

The above-mentioned molded material for a vehicle may have a structure including a heat shielding film laminated on the side of the vehicle interior material of the nonwoven fabric layer.

One feature and advantage of the above configuration is that a heat shielding film is provided on the vehicle interior material side of the vehicle molded material. Thereby, the heat insulation performance of the molded material for vehicles can be further improved.

Regarding the above molded material for a vehicle, the vehicle body panel may be a ceiling panel of the vehicle body, and may be surface-adhered to the ceiling panel by the bonding layer.

One feature and advantage of the above configuration is that the vehicle molding material is disposed on the ceiling panel of the vehicle body and functions as a reinforcing member that supplements the surface rigidity of the ceiling panel. By disposing the vehicle molding material on the ceiling panel, which occupies a large area of the vehicle body, the rigidity of the vehicle body panel can be effectively increased.

By adopting the above configuration, the present invention can provide a molded material for a vehicle that can improve the rigidity performance and vibration damping performance of a vehicle body.

FIG. 2 is a view of the frame of the ceiling portion of the vehicle body and the vehicle molding material attached to the ceiling panel, viewed from the rear inside the vehicle interior. FIG. 1 is a longitudinal cross-sectional view showing the material structure of a molded material for a vehicle according to a first embodiment. It is a figure which shows the example which laminated|stacked the thermal insulation film on the vehicle interior material side of the vehicle molding material. FIG. 7 is a longitudinal cross-sectional view showing the material structure of a molded material for a vehicle according to a second embodiment. FIG. 7 is a longitudinal cross-sectional view showing the material structure of a molded material for a vehicle according to a third embodiment. It is a figure showing the evaluation test method of the molded material for vehicles. FIG. 3 is a diagram showing the rigidity performance of a molded material for a vehicle. It is a figure showing the vibration damping performance of the molded material for vehicles. FIG. 3 is a diagram showing the heat insulation performance of a molded material for a vehicle.

<First embodiment>
Embodiments of the present invention will be described below with reference to the drawings. As a vehicle molding material according to this embodiment, a ceiling molding material 1 to be bonded to a ceiling panel P (vehicle body panel) of a vehicle body will be described. As shown in FIG. 1, a reinforcement R is provided across the ceiling panel P as a reinforcing member in the left-right direction of the vehicle body. The number of reinforcements R is set depending on the required strength of the roof of the vehicle body. The ceiling molding material 1 can be attached to the ceiling panel P, for example, in each area divided by this reinforcement R.

The ceiling molding material 1 is disposed between a ceiling panel P and a ceiling interior material (not shown) in the thickness direction of the ceiling of the vehicle body. As shown in FIG. 2, the ceiling molding material 1 includes a core material 5 and first and second fiber layers 6 and 7 laminated on both sides of the core material 5, and is hardened with a thermosetting resin. Equipped with a molded body. A boundary layer 8 and a bonding layer 9 are laminated on the entire surface of the first fiber layer 6 on the ceiling panel P side (the upper side shown in FIG. 2) in the molded body. A nonwoven fabric layer 12 is laminated on the ceiling interior material side of the second fiber layer 7 (lower side shown in FIG. 2).

The core material 5 is provided to maintain the shape and ensure the rigidity of the ceiling molding material 1, and is formed into a surface shape that follows the surface of the ceiling panel P. As the core material 5 according to this embodiment, a semi-rigid urethane foam made of urethane resin foam is selected.

A first fiber layer 6 is applied to the surface of the core material 5 facing the ceiling panel P, and a second fiber layer 7 is applied to the surface facing the ceiling interior material, each coated with a thermosetting adhesive 13 (thermosetting resin). Laminated through. The first and second fiber layers 6 and 7 are provided to maintain the shape and ensure the rigidity of the ceiling molding material 1. The surfaces of these fiber layers 6 and 7 are coated with or impregnated with a thermosetting adhesive 13, and are bonded to both surfaces of the core material 5, respectively. A glass fiber mat is selected for the first and second fiber layers 6,7. The glass fiber mat is formed into a sheet shape by cutting chopped strands of inorganic fiber glass into appropriate lengths and hardening them with an appropriate binder.

These fiber layers 6 and 7 may be made by hardening glass fibers with a binder without cutting them (continuous mat). Alternatively, spunlace, spunbond nonwoven fabric, glass paper, or glass fiber woven fabric may be used. Moreover, the basis weight in the embodiment can be selected to suit the required strength and other various conditions.

The fiber reinforcing materials used for these fiber layers 6 and 7 include inorganic fibers such as chopped strands, and organic fibers such as jute, kenaf, ramie, hemp, sisal, and bamboo. It is also possible to select appropriate natural fibers and make them into a sheet or mat shape using a binder such as acrylic or by needle processing.

As the thermosetting adhesive 13, a thermosetting resin made of isocyanate resin is selected. Isocyanate is suitable from the viewpoint of being easily compatible with the core material 5 made of urethane foam of the semi-hard layer. Note that the thermosetting adhesive 13 is not limited to isocyanate resin, and can be selected as appropriate. The thermosetting adhesive 13 is applied by spraying, roll coater, or the like. As described above, the strength of the ceiling molding material 1 can be increased by having a structure in which the fiber layers 6 and 7 containing a thermosetting resin and the core material 5 are laminated.

A boundary layer 8 and a bonding layer 9 are laminated on the surface of the first fiber layer 6 facing the ceiling panel P. The bonding layer 9 is provided for bonding the ceiling molding material 1 to the ceiling panel P. Further, the boundary layer 8 is laminated between the first fiber layer 6 and the bonding layer 9. Since it is difficult to directly apply the adhesive as the bonding layer 9 to the glass fiber mat (first fiber layer 6) having a coarse basis weight, the bonding layer 9 is applied to the first fiber layer 6 through the boundary layer 8. are laminated on.

The boundary layer 8 is composed of a two-layer laminate consisting of a thermoplastic bonding film 15 and a protective nonwoven fabric 16. For example, a polypropylene film is selected as the bonding film 15. The first fiber layer 6 and the protective nonwoven fabric 16 are joined by this joining film 15 . For example, a spunbond nonwoven fabric is selected as the protective nonwoven fabric 16. Spunbond nonwoven fabric is suitable because it has good adhesion to adhesives. Moreover, the nonwoven fabric is hardened with an adhesive, which contributes to the rigidity of the ceiling molding material 1.

The bonding layer 9 has a structure that allows surfaces in contact with the ceiling panel P to be bonded to each other. Specifically, the bonding layer 9 can be bonded to the surface of the ceiling panel P to bond the molded body in which the fiber layers 6 and 7 are laminated to the core material 5 to the ceiling panel P. For example, an acrylic adhesive is selected as the bonding layer 9. The adhesive is applied to the surface of the protective nonwoven fabric 16 in the boundary layer 8. Further, for the bonding layer 9, spiral coating, adhesive, tape, etc. can be selected.

A nonwoven fabric layer 12 is laminated on the ceiling interior material side of the second fiber layer 7. The nonwoven fabric layer 12 prevents exposure of the glass fibers of the glass fiber mat having a coarse basis weight and protects the surface of the second fiber layer 7. For the nonwoven fabric layer 12, for example, a needle punched nonwoven fabric is selected.

As shown in FIG. 3, the ceiling molding material 1 may have a structure in which a heat shielding film 18 is laminated on the surface (ceiling interior material side) of the nonwoven fabric layer 12. For example, an aluminum vapor-deposited sheet can be selected as the heat shielding film 18. By providing the heat shielding film 18, it is possible to further suppress the temperature rise in the vehicle interior. Note that, instead of the nonwoven fabric layer 12, a structure may be adopted in which a heat shielding film 18 is directly laminated on the second fiber layer 7.

The ceiling molding material 1 is surface-adhered to the ceiling panel P by a bonding layer 9, and functions as a reinforcing member that supplements the surface rigidity of the ceiling panel P. Due to the above structure, the ceiling molding material 1 has the combined performance of heat insulation, vibration damping, sound absorption and insulation, rigidity, and dew condensation reduction. The ceiling molding material 1 can be attached to the entire surface of the ceiling panel P by removing the reinforcement R. If the vehicle is covered with existing reinforcements R, the ceiling molding material 1 may be bonded to each area between the reinforcements R.

<Effects of embodiment (first embodiment)>
The ceiling molding material 1 (vehicle molding material) according to the first embodiment has a structure in which fiber layers 6 and 7 are laminated on both sides of a core material 5 and solidified with a thermosetting resin (synthetic resin). , is formed into an arbitrary shape according to the shape of the ceiling panel P (vehicle body panel). The ceiling molding material 1 functions as a reinforcing member that supplements the surface rigidity of the ceiling panel P by being surface-adhered to the ceiling panel P by the bonding layer 9. Thereby, the strength of the ceiling panel P can be improved. Further, the generation of a gap between the ceiling molding material 1 and the ceiling panel P can be suppressed, and the vibration damping performance of the vehicle body can be improved. Furthermore, the ceiling molding material 1 has a structure in which a core material 5 and fiber layers 6 and 7 are laminated, and even when it is attached to a ceiling panel P over a wider area, an increase in weight can be suppressed. That is, the ceiling molding material 1 can be attached to the entire surface of the ceiling panel P, and the effects of surface rigidity and vibration damping performance can be exerted over the entire surface of the ceiling panel P.

The ceiling molding material 1 has first and second fiber layers 6 and 7 containing glass fibers laminated on both sides of a core material 5 containing urethane resin, and these layers are coated with a thermosetting adhesive 13 (thermosetting adhesive 13). resin) and are integrally shaped. Thereby, the shape of the ceiling molding material 1 is maintained, and the rigidity can be further increased. Therefore, the ceiling molding material 1 functions as a reinforcing member that supplements the surface rigidity of the ceiling panel P, and even if the vehicle body has few iron reinforcing members, the strength of the ceiling panel P can be ensured. That is, it is possible to have a structure in which the number of iron reinforcing members corresponding to the strength supplemented by the ceiling molding material 1 is reduced. Moreover, the ceiling molding material 1 has a structure in which a core material 5 whose specific gravity is lighter than that of an iron reinforcing member and fiber layers 6 and 7 are laminated. Therefore, when the ceiling molding material 1 is disposed in a limited space between the ceiling panel P and the ceiling interior material (vehicle interior material), the weight in that region can be reduced. Therefore, in addition to improving the surface rigidity and vibration damping performance of the vehicle body panel, it is possible to reduce the weight of the vehicle body.

The ceiling molding material 1 has fiber layers 6 and 7 containing glass fibers laminated on both sides of a core material 5 made of urethane resin foam, which are bonded with a thermosetting adhesive 13 and shaped into one piece. The configuration is as follows. By disposing this ceiling molding material 1, in addition to reducing the weight of the vehicle body and improving the surface rigidity of the ceiling panel P, it is possible to improve the vibration damping performance of the ceiling panel P. Furthermore, the structure in which the urethane resin foam and the glass fiber mat are laminated can improve the heat insulation performance of the ceiling molding material 1.

In the ceiling molding material 1, a nonwoven fabric layer 12 is provided on the surface of the second fiber layer 7 on the ceiling interior material side. Thereby, the sound absorption performance and sound insulation performance of the ceiling molding material 1 can be improved. Moreover, when the heat shielding film 18 is provided on the ceiling interior material side of the ceiling molding material 1, the heat insulation performance of the ceiling molding material 1 can be further improved.

A boundary layer 8 consisting of a thermoplastic bonding film 15 and a protective nonwoven fabric 16 is provided between the first fiber layer 6 and the bonding layer 9. Although the first fiber layer 6 containing glass fibers has a coarse basis weight, the provision of the boundary layer 8 makes it easier to laminate the bonding layer 9.

The ceiling molding material 1 (vehicle molding material) is disposed on the ceiling panel P of the vehicle body, and functions as a reinforcing member that supplements the surface rigidity of the ceiling panel P. By disposing the ceiling molding material 1 on the ceiling panel P, which occupies a large area in the vehicle body, the rigidity of the vehicle body can be effectively increased.

The ceiling molding material 1 can be disposed over the entire surface of the ceiling panel P in place of the reinforcement R of the reinforcing member. That is, since surface rigidity is ensured by surface-adhering the ceiling molding material 1 to the ceiling panel P, reinforcement R can be reduced. By reducing the number of steel reinforcing members, the weight of the vehicle body can be reduced. The ceiling molding material 1 can be disposed over a wide area of the ceiling panel P, and the rigidity of the ceiling panel P can be made uniform. Moreover, by removing the reinforcement R, the vehicle interior space can be made larger. That is, the degree of freedom in setting the layout around the ceiling in the vehicle interior increases.

By forming the ceiling molding material 1 into a molded body that conforms to the shape of the surface of the ceiling panel P, generation of distortion in the ceiling molding material 1 can be suppressed. Moreover, the gap between the ceiling molding material 1 and the ceiling panel P whose surfaces are bonded together with an adhesive or the like can be reduced, and vibration damping performance is improved. In other words, it is possible to reduce the sound of rain that is transmitted from the roof of the vehicle body into the vehicle interior. Moreover, by eliminating the gap between the ceiling molding material 1 and the ceiling panel P, it is possible to suppress the occurrence of dew condensation.

The structure of the ceiling molding material 1 can be changed depending on required performance such as heat insulation, vibration damping, sound absorption and insulation, rigidity, and reduction of dew condensation. For example, by using glass paper, spunlace, or spunbond nonwoven fabric for the first and second fiber layers 6 and 7, the weight and cost of the ceiling molding material 1 can be reduced. Further, by using spiral coating of viscous liquid, adhesive, tape, etc. as the bonding layer 9, it is possible to improve rigidity and damping properties and reduce weight.

<Second embodiment>
Next, a second embodiment will be described. The vehicle molding material according to this embodiment is a ceiling molding material 21 that is bonded to a ceiling panel P (vehicle body panel) of a vehicle body, and as in the first embodiment, in the thickness direction of the ceiling of the vehicle body, It is arranged between the panel P and the ceiling interior material (not shown). Note that descriptions of the structure, function, etc. of the ceiling molding material 21 that are common to the first embodiment will be omitted, and different structures and the like will be explained.

As shown in FIG. 4, the ceiling molding material 21 includes a core material 23 having a planar shape along the surface of the ceiling panel P, and fiber layers 24 laminated on both sides of the core material 23. It is equipped with a molded body solidified with synthetic resin). Further, a bonding layer 29 is laminated on the entire surface of the molded body on the ceiling panel P side, which is capable of bonding the surfaces in contact with the ceiling panel P.

The core material 23 is provided to maintain the shape and ensure the rigidity of the ceiling molding material 21, and is made of a cotton blend material in which glass fibers 26 and thermoplastic resin 27 are mixed. This cotton blend material can be formed by either a dry method typified by cross layering or airlay, or a wet method typified by a papermaking method. The thermoplastic resin 27 in the dry method may be selected from thermoplastic synthetic fibers such as polyethylene fibers, polyester fibers, and polypropylene fibers. As the thermoplastic resin 27 when a wet method (paper making method) is used, a powder of polyethylene, polyester, polypropylene, etc. may be selected. The glass fiber 26 functions as a fiber reinforcing material that increases the strength of the core material 23. As the fiber reinforcing material included in the core material 23, in addition to glass fiber, natural fibers such as basalt fiber, carbon fiber, kenaf (western hemp), and bamboo may be appropriately selected.

A nonwoven fabric is laminated as a fiber layer 24 on both sides of the core material 23 . This nonwoven fabric is laminated to prevent exposure of the glass fibers 26 contained in the core material 23, and for example, a spunlace nonwoven fabric is selected.

The molded body of the ceiling molding material 21 is produced by a heating process in which a laminate consisting of a core material 23 and a fiber layer 24 is heated and softened, and a laminate heated in the heating process is sandwiched between both sides between press molds and cooled while being processed. It is formed into a surface shape that follows the surface of the ceiling panel P through a press molding process. That is, the thermoplastic resin 27 contained in the core material 23 is thermally melted in the heating process, thereby functioning as a binder, and the surfaces where the core material 23 and the fiber layer 24 are in contact are bonded together. The core material 23 and the fiber layer 24 are integrally molded by solidifying the thermoplastic resin by cold pressing in the molding process.

For example, an acrylic adhesive is selected for the bonding layer 29. The adhesive is applied to the surface of the nonwoven fabric on the ceiling panel P side of the molded body. Further, as the bonding layer 29, spiral coating, adhesive, tape, etc. can be selected.

The ceiling molding material 21 may have a structure in which a heat shielding film is provided on the ceiling interior material side. Thereby, the heat insulation performance of the ceiling molding material 21 can be further improved. Further, the configuration of the ceiling molding material 21 may be changed as appropriate depending on the required performance such as heat insulation, vibration damping, sound absorption and insulation, rigidity, and reduction of dew condensation.

<Effects of embodiment (second embodiment)>
The ceiling molding material 21 (vehicle molding material) according to the second embodiment has a structure in which fiber layers 24 are laminated on both sides of a core material 23 and solidified with thermoplastic resin (synthetic resin), and the ceiling panel It is shaped into an arbitrary shape according to the shape of P (vehicle body panel). The ceiling molding material 21 functions as a reinforcing member that supplements the surface rigidity of the ceiling panel P by being surface-adhered to the ceiling panel P by the bonding layer 29 . Thereby, the strength of the ceiling panel P can be improved. Further, the generation of a gap between the ceiling molding material 21 and the ceiling panel P can be suppressed, and the vibration damping performance of the vehicle body can be improved. Furthermore, the ceiling molding material 21 has a structure in which a core material 23 and a fiber layer 24 are laminated, and even when it is attached to a ceiling panel P over a wider area, an increase in weight can be suppressed. That is, the ceiling molding material 21 can be attached to the entire surface of the ceiling panel P, and the effects of surface rigidity and vibration damping performance can be exerted over the entire surface of the ceiling panel P.

In the ceiling molding material 21, fiber layers 24 made of nonwoven fabric are laminated on both sides of a core material 23 containing glass fibers 26 and thermoplastic resin 27, and these layers are integrally shaped. By disposing this ceiling molding material 21, the vibration damping performance of the ceiling panel P can be further improved. Moreover, by laminating a nonwoven fabric as the fiber layer 24, it is possible to improve the sound absorption performance and sound insulation performance of the ceiling molding material 21.

By forming the ceiling molding material 21 into a molded body that follows the shape of the surface of the ceiling panel P, it is possible to suppress the occurrence of distortion in the ceiling molding material 21, as in the first embodiment. Furthermore, it is possible to reduce the sound of rain that is transmitted from the roof of the vehicle body into the vehicle interior. Moreover, by eliminating the gap between the ceiling molding material 21 and the ceiling panel P, it is possible to suppress the occurrence of dew condensation.

<Third embodiment>
Next, a third embodiment will be described. The vehicle molding material according to this embodiment is a ceiling molding material 31 that is bonded to a ceiling panel P (vehicle body panel) of a vehicle body, and as in the first embodiment, in the thickness direction of the ceiling of the vehicle body, It is arranged between the panel P and the ceiling interior material (not shown). Note that the explanation of the structure, function, etc. of the ceiling molding material 31 that is common to the first embodiment will be omitted, and the different structure, etc. will be explained.

As shown in FIG. 5, the ceiling molding material 31 includes a core material 33 made of a fiber molding having a planar shape along the surface of the ceiling panel P. A bonding layer 37 capable of bonding the surfaces in contact with the ceiling panel P is laminated on the entire surface of the core material 33 on the ceiling panel P side.

The core material 33 is composed of a fiber molded body solidified with a thermoplastic resin 35. For the core material 33, for example, a mixed cotton material containing polypropylene, which is a thermoplastic resin, and polyethylene terephthalate is selected. The core material 33 is molded through a heating process and a molding process. Since polyethylene terephthalate has a higher melting point than polypropylene, by setting the heating temperature in the heating step to match the melting temperature of polypropylene, only the polypropylene is thermally melted and functions as a binder. Then, by cold pressing in the molding process, the polypropylene is solidified and the core material 33 is molded.

For example, an acrylic adhesive is selected for the bonding layer 37. The adhesive is applied to the surface of the core material 33 on the ceiling panel P side. Further, as the bonding layer 37, spiral coating, adhesive, tape, etc. can be selected.

The ceiling molding material 31 may have a structure in which a heat shielding film is provided on the ceiling interior material side. Thereby, the heat insulation performance of the ceiling molding material 31 can be further improved. Further, the configuration of the ceiling molding material 31 may be changed as appropriate depending on the required performance such as heat insulation, vibration damping, sound absorption and insulation, rigidity, and reduction of dew condensation.

<Effects of embodiment (third embodiment)>
The core material 33 of the ceiling molding material 31 (vehicle molding material) is composed of a fiber molded body solidified with a thermoplastic resin 35, and is shaped into an arbitrary shape according to the shape of the ceiling panel P (vehicle body panel). has been done. The ceiling molding material 31 functions as a reinforcing member that supplements the surface rigidity of the ceiling panel P by being surface-adhered to the ceiling panel P by the bonding layer 37. Thereby, the strength of the ceiling panel P can be improved. Further, it is possible to suppress the generation of a gap between the ceiling molding material 31 and the ceiling panel P over the entire surface of the ceiling panel P, and it is possible to improve the vibration damping performance of the vehicle body. Furthermore, even when the fiber molded body constituting the core material 33 is attached to the ceiling panel P over a wider area, an increase in weight can be suppressed. That is, the ceiling molding material 31 can be attached to the entire surface of the ceiling panel P, and the effects of surface rigidity and vibration damping performance can be exhibited over the entire surface of the ceiling panel P.

By making the ceiling molding material 31 a fiber molding that conforms to the shape of the surface of the ceiling panel P, it is possible to suppress the occurrence of distortion in the ceiling molding material 31, as in the first embodiment. Furthermore, it is possible to reduce the sound of rain that is transmitted from the roof of the vehicle body into the vehicle interior. Furthermore, by eliminating the gap between the ceiling molding material 31 and the ceiling panel P, it is possible to suppress the occurrence of dew condensation.

[Example]
Examples of the present invention and their effects will be described below. As the structure of the ceiling molding material 1, the core material 5 was made of urethane shaped using an adhesive, and the first and second fiber layers 6 and 7 were glass fiber mats coated with isocyanate resin. Further, for the boundary layer 8, a polypropylene film and a spunbond nonwoven fabric were used. The spunbond nonwoven fabric is coated with an acrylic adhesive that becomes the bonding layer 9. A needle-punched nonwoven fabric is laminated on the ceiling interior material side of the second fiber layer 7.

A bending test was conducted assuming a state in which the ceiling molding material 1 according to the example was bonded to a ceiling panel P. Specifically, a sample Q in which a 150 mm square ceiling molding material 1 and a sheet metal are bonded together is supported at two points as shown in FIG. The distance L between the fulcrums is set to 100 mm. A three-point bending test was performed by applying a load with a load element T from above the supported sample Q, and the deflection was measured. FIG. 7 is a diagram showing the rigidity of Examples, Comparative Example 1, and Comparative Example 2, where the vertical axis is load (N) and the horizontal axis is deflection (mm). Note that in Comparative Example 1, the load and deflection were similarly measured for only the sheet metal used in the conventional ceiling panel P, and for Comparative Example 2, only the ceiling molding material 1 was used. As shown in FIG. 7, the maximum load measured in Example 1 is approximately twice that of Comparative Example 1. That is, when the ceiling molding material 1 of the example is bonded to the ceiling panel P, the rigidity is improved.

Next, the ceiling molding material 1 according to the example was bonded to the ceiling panel P from which the reinforcement R was removed, and a vibration damping performance evaluation test was conducted. FIG. 8 is a diagram showing the vibration damping performance of Example and Comparative Example 3, where the vertical axis is the vibration magnitude (dB) and the horizontal axis is the sound frequency (Hz). In Comparative Example 3, felt was bonded to a ceiling panel P provided with a conventional reinforcement R. As shown in FIG. 8, when the ceiling molding material 1 of the example is bonded to the ceiling panel P, the damping performance is maintained or improved compared to Comparative Example 3 at almost all the measured frequencies.

Next, the ceiling molding material 1 according to the example was bonded to the ceiling panel P, and a heat insulation performance evaluation test was conducted. FIG. 9 is a diagram showing the progress of temperature rise in the vehicle interior in Example, Comparative Example 3, and Comparative Example 4, with the vertical axis representing temperature (° C.) and the horizontal axis representing elapsed time (minutes). Comparative Example 4 uses Thinsulate (registered trademark) instead of felt in Comparative Example 3. As shown in FIG. 9, when the ceiling molding material 1 of the example is bonded to the ceiling panel P, the temperature rise in the vehicle interior is suppressed compared to Comparative Examples 3 and 4. For example, after 15 minutes, the temperature increase in the example is suppressed to about 60% compared to comparative example 3. Furthermore, even after 30 minutes have elapsed, the temperature in the example is kept lower than that in Comparative Examples 3 and 4.

The molded material for a vehicle according to the present invention is not limited to the appearance and configuration described in the above embodiments, but may be modified in various forms by various changes, additions, deletions, and combinations of configurations without changing the gist of the present invention. It is something that can be implemented.

As the vehicle molding material of the above embodiment, an example of a ceiling molding material disposed between the ceiling panel P and the ceiling interior material is shown, but the present invention is not limited to this, and vehicle molding materials in other parts of the vehicle are shown. It can also be applied as

The molded material for a vehicle according to the present invention may have a configuration in which neither a boundary layer nor a nonwoven fabric layer is provided, depending on the material configurations selected for the first and second fiber layers.

1 Molding material for ceilings (molding material for vehicles)
5 Core material 6 First fiber layer 7 Second fiber layer 8 Boundary layer 9 Bonding layer 12 Nonwoven fabric layer 13 Thermosetting adhesive (thermosetting resin)
15 Bonding film 16 Protective nonwoven fabric 18 Heat shielding film 21 Ceiling molding material (vehicle molding material)
23 Core material 24 Fiber layer 26 Glass fiber 27 Thermoplastic resin 29 Bonding layer 31 Ceiling molding material (vehicle molding material)
33 Core material 35 Thermoplastic resin 37 Bonding layer P Ceiling panel (vehicle body panel)
R Reinforcement

Claims (7)

A vehicle molding material disposed between a vehicle body panel and a vehicle interior material,
a molded body solidified with a synthetic resin, including a core material having a planar shape along the surface of the vehicle body panel, and fiber layers laminated on both sides of the core material;
a bonding layer laminated on the entire surface of the molded body on the vehicle body panel side and capable of bonding surfaces in contact with the vehicle body panel;
A molded material for a vehicle, which functions as a reinforcing member that supplements the surface rigidity of the vehicle body panel by being surface-adhered to the vehicle body panel by the bonding layer. A vehicle molding material disposed between a vehicle body panel and a vehicle interior material,
a core material made of a fiber molded body solidified with a thermoplastic resin and having a planar shape along the surface of the vehicle body panel;
a bonding layer laminated on the entire surface of the molded body on the vehicle body panel side and capable of bonding surfaces in contact with the vehicle body panel;
A molded material for a vehicle, which functions as a reinforcing member that supplements the surface rigidity of the vehicle body panel by being surface-adhered to the vehicle body panel by the bonding layer. The molded material for a vehicle according to claim 1,
The molded body is
The core material containing urethane resin;
a first fiber layer containing glass fibers, which is laminated on the surface of the core material on the vehicle body panel side via a thermosetting resin;
a second fiber layer containing glass fibers, which is laminated on the surface of the core material on the vehicle interior material side via a thermosetting resin;
A molded material for a vehicle, comprising, between the first fiber layer and the bonding layer, a thermoplastic bonding film and a protective nonwoven fabric laminated on a surface of the bonding film on the bonding layer side. The molded material for a vehicle according to claim 1,
The molded body is
the core material containing glass fiber and thermoplastic resin;
A molded material for a vehicle, comprising: the fiber layer made of a nonwoven fabric. The vehicle molding material according to claim 3,
A molded material for a vehicle, comprising a nonwoven fabric layer laminated on a surface of the second fiber layer on the vehicle interior material side. The molded material for a vehicle according to claim 5,
A molded material for a vehicle, comprising a heat shielding film laminated on the side of the vehicle interior material of the nonwoven fabric layer. The molded material for a vehicle according to any one of claims 1 to 6,
The vehicle body panel is a ceiling panel of the vehicle body,
A molded material for a vehicle that is surface-adhered to the ceiling panel by the bonding layer.

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