JP4820599B2 - 車両用成形天井の製造方法 - Google Patents

車両用成形天井の製造方法 Download PDF

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JP4820599B2
JP4820599B2 JP2005219493A JP2005219493A JP4820599B2 JP 4820599 B2 JP4820599 B2 JP 4820599B2 JP 2005219493 A JP2005219493 A JP 2005219493A JP 2005219493 A JP2005219493 A JP 2005219493A JP 4820599 B2 JP4820599 B2 JP 4820599B2
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skin material
molded ceiling
nonwoven fabric
fabric layer
substrate
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JP2007030773A (ja
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崇 小島
芳明 加藤
和年 宗宮
亮一 川畑
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Howa Co Ltd
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Howa Textile Industry Co Ltd
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Priority to JP2005219493A priority Critical patent/JP4820599B2/ja
Priority to US11/989,413 priority patent/US20090145538A1/en
Priority to CN200680026528A priority patent/CN100586761C/zh
Priority to PCT/JP2006/314674 priority patent/WO2007013455A1/ja
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/14—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor using multilayered preforms or sheets
    • B29C51/145—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor using multilayered preforms or sheets having at least one layer of textile or fibrous material combined with at least one plastics layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B1/00—Layered products having a non-planar shape
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B32B3/04—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions characterised by at least one layer folded at the edge, e.g. over another layer ; characterised by at least one layer enveloping or enclosing a material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/06—Interconnection of layers permitting easy separation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
    • B60R13/02—Internal Trim mouldings ; Internal Ledges; Wall liners for passenger compartments; Roof liners
    • B60R13/0212—Roof or head liners
    • B60R13/0225—Roof or head liners self supporting head liners
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2793/00—Shaping techniques involving a cutting or machining operation
    • B29C2793/009—Shaping techniques involving a cutting or machining operation after shaping
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/02—Combined thermoforming and manufacture of the preform
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/08—Deep drawing or matched-mould forming, i.e. using mechanical means only
    • B29C51/082—Deep drawing or matched-mould forming, i.e. using mechanical means only by shaping between complementary mould parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C63/00—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor
    • B29C63/0004—Component parts, details or accessories; Auxiliary operations
    • B29C63/0013—Removing old coatings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3005—Body finishings
    • B29L2031/3011—Roof linings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0278—Polyurethane
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/10—Properties of the layers or laminate having particular acoustical properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/748—Releasability
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Textile Engineering (AREA)
  • Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
  • Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
  • Shaping Of Tube Ends By Bending Or Straightening (AREA)
  • Laminated Bodies (AREA)

Description

本発明は、車両用成形天井の周縁部、或いは開口部の端縁等が表皮材により被覆処理される車両用成形天井の製造方法に関するものである。
車両用成形天井は、一般に、成形面が所要曲面に形成された成形型に、繊維系，段ボール系，ウレタン系，発泡オレフィン系等の基材を、ファブリック，クロス，ニット等と称される布帛からなる表皮材とともにセットして加熱・加圧することにより製造される。
また、該成形天井に例えばサンルーフ用の開口部が形成された場合、開口によって生じた基材の端縁に表皮材を巻き込むことにより該端縁が室内側に直接露呈しないように被覆される。また、成形天井の周縁部についても同様の被覆処理がされる。
また、下記特許文献１，２には成形天井の端縁を表皮材により被う製造方法が開示されている。
特開平１０−２６４７３４号公報 特開平１０−２６４７３５号公報
ところで、上記従来の製造方法では、基材を成形するための第１のプレス工程と、表皮材を被着するための第２のプレス工程とを要するので、工程数が増すという問題点、および、基材に表皮材を接着させるためのホットメルトフィルムが硬化するので、表皮材によって基材の端縁を被覆するためには硬化したホットメルトフィルムを除去しなければならない等の問題があった。
そこで本発明は、これらの問題を生じさせることなく、少ない工程で成形天井の端縁の被覆処理がなされるようにし、生産性を向上できる車両用成形天井の製造方法を提供しようとするものである。
上記課題を解決するため本発明に係る車両用成形天井の製造方法は、表皮材は、布帛の裏面にウレタンフォームシートを貼着するとともに、該ウレタンフォームシートの裏面に不織布層を介在させて接着剤非透過性の紙を貼着してなるものであり、成形面が所要曲面に形成された成形型に基材を前記表皮材とともにセットして加熱・加圧し該基材と表皮材とを接着させることにより成形天井を成形した後、該成形天井の裏側から基材に切り込みを入れて該基材の端材のみを前記不織布層にて表皮材からはがし、接着剤を該表皮材の端材をはがした部分に塗布し該表皮材を該基材の端縁に巻き込んで接着することで該端縁を該表皮材によって被覆することを特徴とする。
また、本発明に係る車両用成形天井の製造方法は、上記表皮材は、布帛と、ウレタンフォームシートと、不織布層を有した接着剤非透過性の紙とをフレームラミネート工法により貼着したものであることを特徴とする。
成形天井を成形した後に基材に切り込みを入れることにより出来た端材を不織布層にて分離させることで該端材を容易にはがすことができる。このため端縁処理が簡単にできるようになる。また、所要工程を少なくできることと相俟って生産性が向上する。
次に図面とともに本発明の実施例を説明する。図１に示すように、基材１は半硬質ウレタンフォームからなる芯材２の両面に熱硬化性接着剤を塗布してガラス繊維マット３，４を積層するとともに、その裏面に非通気性フィルム５を介在させＰＥＴ樹脂繊維不織布からなる裏材６を積層してなる。また、表皮材７は、図２に示したフレームラミネート工法により製造されるもので、同図において、８はロール状に巻回されたファブリック等の布帛、９はロール状に巻回されたウレタンフォームシート、１０はロール状に巻回された裏打材である。裏打材１０は、図３に拡大して示したように接着剤非透過性の紙１１の片面にＰＥＴ樹脂繊維を周知のスパンレース法によって交絡してなる不織布層１２を設けてなるものである。このフレームラミネート工法では、ガスバーナ１３の火炎によりウレタンフォームシート９の一方の表面をあぶって溶融し、そこへ裏打材１０の不織布層１２側を重合させてロール１４，１５間に通すとともに、ガスバーナ１６の火炎により該ウレタンフォームシート９の他方の表面をあぶって溶融し布帛８を重合させてロール１５，１７間に通すことにより、図１に示した断面構造の表皮材７をロール状に巻き取り製造する。なお、上記紙１１の目付量は５〜２００ｇ／ｍ２（好ましくは２５ｇ／ｍ２）のものを使用できる。また上記不織布層１２の目付量は５〜２００ｇ／ｍ２（好ましくは４０ｇ／ｍ２）のものを使用できる。
そして、図４に示したように、成形面が所要曲面に形成された成形型１８，１９間に該基材１を表皮材７とともにセットし加熱・加圧することにより、該基材１と表皮材７との間に前記熱硬化性接着剤を溶融浸透させて該基材１と表皮材７とを接着させる。このとき紙１１はこの加熱・加圧時に該熱硬化性接着剤が不織布層１２に浸透するのを防ぐ。これによって、図５に示したような所要の立体曲面状の成形天井２０となる。図５は成形天井２０の基材１側からの斜視図であって、２０ａはサンルーフ用開口部を形成するために基材１側に僅かに盛り上がるように形成された丘状部、２０ｂ，２０ｃは下面（室内側）にサンバイザーを収容できるように基材１側に僅かに盛り上がるように形成された丘状部を示す。
次いで、図６に示したように該成形天井２０の丘状部２０ａに基材１側よりカッターナイフ２１により切り込みを入れ、該基材１にサンルーフ等の必要な開口部を形成する。そしてこの切り込みによって出来た端材１ａのみを図７に示したように前記不織布層１２にて表皮材７からはがす。このとき不織布層１２は接着剤が浸透していないことから分離し易く、ウレタンフォームシート９が強く引っ張られて破るようなことはなく、端材１ａのみを容易に離脱することができる。そして、このウレタンフォームシート９に接着剤を塗布し、該表皮材７の端縁を図８に示したように該基材１の端縁に巻き込んで接着することにより、該基材１の端縁を表皮材７によって被覆でき見栄えのよいものとなる。
なお、紙１１を設けたことにより表皮材７に接着剤が染み出すおそれがなく、外観を美しく仕上げることができる。また、不織布層１２を設けたことから該不織布層が吸音層として機能し、この成形天井２０は吸音性能も優れたものとなる。
なお、この実施例ではサンルーフ用開口部について説明したが、成形天井２０の周縁部、或いはマップランプやアシストグリップ等を装着するための孔の内縁部についても同様の端縁処理をすることが可能である。
このように本発明では、成形型によって加熱・加圧することにより基材を所要曲面に付形することと表皮材を被着することとが同時になされるので、所要工程を少なくできるとともに、不織布層を予め介在させたことによって基材と表皮材とがはがれ易くなるので、基材の端材の除去が容易となり、端縁処理が簡単にできるようになり、成形天井の生産性を向上させる顕著な効果がある。
本発明に係る車両用成形天井の基材と表皮材の縦断面図。 本発明に係る車両用成形天井の表皮材を製造するフレームラミネート工法の概略図。 本発明に係る車両用成形天井の裏打材の拡大縦断面図。 本発明に係る車両用成形天井の製造方法を示す成形型の縦断面図。 本発明に係る車両用成形天井の斜視図。 本発明に係る車両用成形天井の要部に切り込みを入れたときの縦断面図。 本発明に係る車両用成形天井の要部の端材をはがしたときの縦断面図。 本発明に係る車両用成形天井の要部の縦断面図。
符号の説明
１ 基材
１ａ 端材
７ 表皮材
８ 布帛
９ ウレタンフォームシート
１０ 裏打材
１１ 紙
１２ 不織布層
１８，１９ 成形型
２０ 成形天井
２１ カッターナイフ

Claims (2)

  1. 表皮材は、布帛の裏面にウレタンフォームシートを貼着するとともに、該ウレタンフォームシートの裏面に不織布層を介在させて接着剤非透過性の紙を貼着してなるものであり、成形面が所要曲面に形成された成形型に基材を前記表皮材とともにセットして加熱・加圧し該基材と表皮材とを接着させることにより成形天井を成形した後、該成形天井の裏側から基材に切り込みを入れて該基材の端材のみを前記不織布層にて表皮材からはがし、接着剤を該表皮材の端材をはがした部分に塗布し該表皮材を該基材の端縁に巻き込んで接着することで該端縁を該表皮材によって被覆することを特徴とした車両用成形天井の製造方法。
  2. 請求項１に記載した表皮材は、布帛と、ウレタンフォームシートと、不織布層を有した接着剤非透過性の紙とをフレームラミネート工法により貼着したものである車両用成形天井の製造方法。
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CN200680026528A CN100586761C (zh) 2005-07-28 2006-07-25 车辆用成形顶棚的制造方法
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