JP5626904B2 - Vehicle ceiling material - Google Patents

Description

  The present invention relates to a vehicle ceiling material, and more particularly to a technique for imparting high sound absorption performance to a vehicle ceiling material in which a base material, a skin layer, a fiber layer, and a back surface layer are laminated.

  2. Description of the Related Art Conventionally, a vehicle ceiling material is known in which a skin layer is provided on the surface side of a base material and a back surface layer is provided on the back surface side of the base material (see, for example, Patent Document 1).

  FIG. 11 is a diagram illustrating a configuration example of a conventional vehicle ceiling material. A vehicle ceiling material 100 includes a urethane base material 101 and a surface-side fiber layer disposed so as to sandwich the base material 101 therebetween. 102 and a back surface side fiber layer 103, a skin layer 104 provided on the surface of the front surface side fiber layer 102 and forming a ceiling surface of the passenger compartment, and a back surface layer 105 provided on the back surface of the back surface side fiber layer 103. It becomes.

  Of the vehicle ceiling material 100, the base material 101, the front-side fiber layer 102, the back-side fiber layer 103, and the skin layer 104 are made of a breathable material. For this reason, the back surface layer 105 is made of a non-breathable material to stop the flow of air from the vehicle interior to the back side of the ceiling material 100 and prevent dust and the like from adhering to the surface of the skin layer 104. Yes.

  A method for manufacturing such a ceiling material 100 will be described with reference to FIG. In FIG. 12, the skin layer 104 is arranged on the upper side and the back surface layer 105 is arranged on the lower side in accordance with the direction of the molding material.

  First, as shown in FIG. 12A, a base material 101, a front surface side fiber layer 102, a back surface side fiber layer 103, a skin layer 104, and a back surface layer 105 are laminated to prepare a molding material 106. An adhesive 107 is applied to the entire surface of the front side fiber layer 102 and the back side fiber layer 103 of the molding material 106 in advance over the entire surface. Next, as shown in FIG. 12B, hot press molding is performed with the molding material 106 sandwiched between the upper mold 108 and the lower mold 109. At this time, the back surface of the skin layer 104 is bonded to the surface of the front surface side fiber layer 102, and the surface of the back surface layer 105 is bonded to the back surface of the back surface side fiber layer 103. Thereby, all the layers are integrated and the ceiling material 100 of a predetermined shape is obtained.

  By the way, while the quietness of the vehicle is required, there is a demand for a ceiling material that further enhances the sound absorption performance. However, in the conventional ceiling material 100, since the sound absorption performance is determined by the foam density of the base material 101 and the thickness of each layer, there is a limit to the improvement of the sound absorption performance.

  Therefore, Patent Document 2 proposes a technique for disposing a damping member between an interior base material (or outflow prevention film) and an infrared reflecting member in a vehicle interior material. In this technique, vibration is absorbed by a damping member to enhance the sound insulation effect.

JP 2003-280666 A JP 2009-126696 A

  However, even in the technique disclosed in Patent Document 2, the vibration damping member is merely one layer stuck on the interior base material or the outflow prevention film, and the sound absorbing performance is similar to the ceiling material 100 described above. Since it is determined by the specifications (foaming density and thickness) of each layer, it is difficult to further improve the sound absorption performance.

  Then, this invention is made | formed in view of such a situation, and is providing the vehicle ceiling material which can improve a sound absorption performance further.

In order to solve the above-described problems, a vehicle ceiling material according to the present invention is provided on a base material, a skin layer provided on the front surface side of the base material and forming a ceiling surface in a vehicle interior, and a back surface side of the base material. A reinforcing fiber layer, an adhesive adhered to the back surface of the fiber layer, and a back layer for airflow prevention adhered to the fiber layer by the adhesive, the fiber layer and the back surface And an adhesive layer on the back surface of the adhesion preventing layer, the adhesive layer being dented on the substrate side and crushed in the adhesion preventing layer. A concave portion that exudes water was provided, and the concave portion and the adhesion preventing layer were bonded to each other with the exuding adhesive.

  In order to solve the above problems, the vehicle ceiling material of the present invention has an adhesion preventing layer that is narrower than the back surface layer, in particular, between the fiber layer and the back surface layer. The concave portion is dented on the substrate side and the adhesive prevention layer is crushed to allow the adhesive to ooze out on the back surface of the adhesion prevention layer, and the concave portion and the adhesion prevention layer are formed by the oozed adhesive. It is characterized by being glued.

  According to the present invention, the back surface layer is prevented from adhering to the fiber layer at a portion overlapping the adhesion preventing layer. Thereby, since a back surface layer is bonded by floating, the sound absorption effect by membrane vibration can be obtained. As a result, it is possible to provide a vehicle ceiling material that can obtain higher sound absorption performance.

It is a perspective view of a vehicle provided with the ceiling material for vehicles of a 1st embodiment concerning the present invention. It is a C arrow line view of FIG. 1, and is a top view of the ceiling material for vehicles. FIG. 2 is a cross-sectional view illustrating a layer configuration of a vehicle ceiling material according to the first embodiment. It is a figure explaining the manufacturing method of the ceiling material for vehicles of 1st Embodiment, (a) is a figure explaining a raw material preparation process, (b) is a figure explaining a formation process. It is a figure explaining the structure of the ceiling material for vehicles of 1st Embodiment, (a) is a top view, (b) is the bb sectional view taken on the line of (a), (c) is c section of (b). It is an enlarged view. It is a figure explaining the manufacturing method and structure of the ceiling material for vehicles of 2nd Embodiment, (a) is a figure explaining a raw material preparation process, (b) is a top view of the ceiling material for vehicles. It is a figure explaining the manufacturing method of the ceiling material for vehicles of 3rd Embodiment, (a) is a figure explaining the structure of a convex part, (b) is a figure explaining the effect | action of a convex part. It is a top view of the ceiling material for vehicles of a 3rd embodiment. It is a top view of the ceiling material for vehicles of a 4th embodiment. It is a figure explaining the manufacturing method and structure of the ceiling material for vehicles of 4th Embodiment, (a) is a figure explaining the structure of a convex part, (b) is a figure explaining the effect | action of a convex part, (c). FIG. 5 is a cross-sectional view illustrating a state where a wire harness is fixed to a recess. It is a figure explaining the basic composition of the conventional ceiling material for vehicles. (A) is sectional drawing explaining the laminated constitution of the conventional vehicle ceiling material, (b) is a figure explaining the manufacturing method of the conventional vehicle ceiling material.

(First embodiment)
Hereinafter, a first embodiment for carrying out the present invention will be described in detail with reference to the accompanying drawings. Note that the same number is assigned to the same element throughout the description of the embodiment. The left and right are the left and right with respect to the traveling direction of the vehicle. The surface of each layer of the ceiling material is a surface facing the passenger compartment, and the back surface of each layer is a surface facing the roof of the vehicle.

  As shown in FIG. 1, the vehicle 10 includes a vehicle body 11, a front wheel 12, a rear wheel 13, and a passenger compartment 14. The vehicle body 11 includes a roof 15 that covers the upper portion of the passenger compartment 14. Inside the roof 15, a vehicular ceiling material 20 is provided that interiors the ceiling surface of the vehicle compartment 14.

  As shown in FIG. 2, the ceiling member 20 has a substantially rectangular shape in plan view, and the front portion 21 is formed in a substantially flat plate shape. A curved portion 22 is formed in the rear portion of the front portion 21 and becomes higher as going to the center. The ceiling member 20 is provided with an opening 23 for attaching an indoor lamp (so-called room lamp or map lamp), an opening 24 for attaching a sun visor, and an opening 25 for attaching a grip.

Next, the layer structure of the ceiling material 20 will be described with reference to FIG.
As shown in FIG. 3, the ceiling material 20 includes a base material 26, a reinforcing surface side fiber layer 27 and a back surface side fiber layer 28 disposed so as to sandwich the base material 26, and the surface side fiber layer 27. A skin layer 31 that is provided on the surface and forms a ceiling surface in the passenger compartment 14 (see FIG. 1) and a back surface layer 32 for airtightness bonded to the back surface of the back surface side fiber layer 28 are laminated. And between the back surface side fiber layer 28 and the back surface layer 32, the narrow adhesion prevention layer 33 whose area is smaller than the back surface side fiber layer 28 is interposed. In FIG. 3, in accordance with the position of each layer in the manufacturing process, the skin layer 31 is disposed on the upper side, and the back surface layer 32 is disposed on the lower side.

  The base material 26 is made of a foam material such as semi-rigid urethane foam. The front-side fiber layer 27 and the back-side fiber layer 28 are made of a fiber material such as a glass mat, and an adhesive S (represented by a number of black dots in the figure) is applied to the entire front and back surfaces. The Each of the front surface side fiber layer 27 and the back surface side fiber layer 28 is a reinforcing layer that reinforces the ceiling material 20, and also serves as an adhesive layer that adheres the skin layer 31 and the back surface layer 32 to the base material 26 side.

  The skin layer 31 is arbitrarily selected from breathable materials such as nonwoven fabric, woven fabric, and knit. The back surface layer 32 is made of a non-breathable material, and is preferably selected from, for example, a heat shielding material such as an aluminum vapor deposition film capable of suppressing a temperature rise in the passenger compartment. As the adhesive S, a moisture curable adhesive such as isocyanate or a thermosetting resin adhesive is suitable. Here, the adhesive S is applied to the front surface side fiber layer 27 and the back surface side fiber layer 28 to adhere the skin layer 31 and the back surface layer 32, but the adhesive agent is applied to or impregnated on the base material 26. It does not matter even if it is made to do. In this case, the adhesive applied or impregnated on the base material 26 is permeated into the front-side fiber layer 27 and the back-side fiber layer 28, and the adhesive is applied to the front surface of the front-side fiber layer 27 and the back surface of the back-side fiber layer 28. Adhere. The skin layer 31 and the back surface layer 32 are bonded to the front surface side fiber layer 27 and the back surface side fiber layer 28, respectively, with the adhered adhesive.

  The length dimension (length in the vehicle length direction) of the adhesion preventing layer 33 is approximately the same as the length of the back surface layer 32. The width dimension (dimension in the vehicle width direction) W1 of the adhesion preventing layer 33 is set smaller than the width dimension W2 of the back surface layer 32 and the back surface side fiber layer 28. The material of the adhesion preventing layer 33 can be selected from any material such as paper or a synthetic resin film. The material which has property is preferable.

Next, the manufacturing method of the ceiling material 20 of 1st Embodiment is demonstrated based on FIG.
The method for manufacturing the ceiling material 20 includes a material preparation step for obtaining a molding material and a molding step for performing hot press molding using the molding material.

  As shown in FIG. 4A, in the material preparation step, the base material 26, the front surface side fiber layer 27, the back surface side fiber layer 28, the skin layer 31 and the back surface layer 32 are laminated, and the back surface side fiber layer 28 and the back surface An anti-adhesion layer 33 is interposed between the layers 32 along the vehicle length direction to obtain a molding material 35. At this time, both the left and right ends (both ends in the vehicle width direction) of the adhesion preventing layer 33 are positioned on the center side by a predetermined width (for example, (W2-W1) / 2) from both ends of the back surface layer 32.

  Next, the molding material 35 is conveyed to the molding die 40 and set. In the molding step, a molding die 40 including a first die (upper die) 41 for shaping the skin layer 31 side and a second die (lower die) 42 for shaping the back surface layer 32 side is used. As shown in (b), the upper die 41 and the lower die 42 are combined and clamped, and the molding material 35 is sandwiched between the upper die 41 and the lower die 42. At this time, the back surface layer 32 and the back surface side fiber layer 28 are brought into contact with each other in the left and right regions outside the adhesion preventing layer 33 in the back surface layer 32. On the other hand, hot press molding is performed between the left and right regions so that the back surface layer 32 and the back surface side fiber layer 28 are not brought into contact with each other by the adhesion preventing layer 33.

  Then, as shown in FIGS. 5 (a) and 5 (b), the back surface layer 32 includes a left and right adhesive region A that is bonded to the back surface side fiber layer 28 and a non-adhesive region B that is prevented from being bonded (FIG. 5 ( a), a region schematically shown by oblique lines).

  That is, as shown in FIG. 5 (c), in the left and right adhesive regions A, the back surface layer 32 and the back surface side fiber layer 28 are firmly bonded with the adhesive S, but in the non-adhesive region B on the center side, The back surface layer 32 and the back surface side fiber layer 28 are not bonded by the adhesion preventing layer 33. Thereby, the floating back layer 32 is obtained. As a result, the back surface layer 32 can vibrate in the direction indicated by the arrow (1), and the sound absorbing performance by membrane vibration can be imparted to the ceiling material 20.

  As described above, according to the first embodiment described above, it is possible to obtain a sound absorption effect by membrane vibration. As a result, the sound absorption performance can be further enhanced. Further, by adjusting the width dimension W1 of the adhesion preventing layer 33, the positions and areas of the adhesion area A and the non-adhesion area B can be adjusted. The sound absorption performance can be adjusted.

(Second Embodiment)
Next, 2nd Embodiment concerning this invention is described based on FIG. In addition, the same code | symbol is attached | subjected to the site | part which is common in 1st Embodiment mentioned above, and the overlapping description is abbreviate | omitted (the same is applied also after 3rd Embodiment).

  In the first embodiment described above, one non-adhesion region is formed using one adhesion prevention layer, but the adhesion prevention layer may be divided into a plurality of sheets in the vehicle width direction. For example, as shown in FIG. 6A, a plurality (two in this case) of adhesion preventing layers 34 are arranged apart from each other in the vehicle width direction between the back surface side fiber layer 28 and the back surface layer 32. In the molding step, the back-side fiber layer 28 and the back-side layer 32 are bonded between the two adjacent adhesion preventing layers 34. As a result, as shown in FIG. 6B, a plurality of non-adhesion regions B1 can be provided, and a space between two adjacent non-adhesion regions B1 can be set as the adhesion region A1.

  According to the second embodiment, in addition to obtaining the same operational effects as those of the first embodiment described above, the back layer 32 can be partially bonded also in regions other than the left and right bonding regions A. Thereby, it can prevent that the back surface layer 32 floats too much near the center. Further, the position and area of each of the adhesion region and the non-adhesion region can be finely adjusted, and the degree of freedom in design can be increased.

(Third embodiment)
Next, 3rd Embodiment concerning this invention is described based on FIG.
As shown in FIG. 7A, in the third embodiment, in the basic configuration of the first embodiment described above, a convex portion 43 that protrudes toward the upper die 41 is provided on the molding surface 42a of the lower die 42. Is. The convex portion 43 is formed to extend in the vehicle length direction. In addition, the structure of the convex part 43 is not limited to the form extended in a vehicle length direction. For example, the protrusions 43 may be formed so as to extend in the vehicle width direction or in an oblique direction, and the plurality of protrusions 43 may be arranged in an arbitrary direction or cross each other.

  The operation of the convex portion 43 will be described. As shown in FIG. 7B, in the molding process, the concave portion 44 is molded on the back surface of the back layer 32 using the convex portion 43. At the same time, the adhesion preventing layer 33 is crushed, and the adhesive S is oozed out on the back surface 33a of the crushed portion. And the recessed part 44 and the adhesion prevention layer 33 are adhere | attached with the adhesive agent S which oozed out. As a result, as shown in FIG. 8, it is possible to provide an adhesion region A2 in which the back surface layer 32 and the adhesion prevention layer 33 are partially adhered, for example, at the central portion of the non-adhesion region B.

  Here, attention is focused on the configuration of the back surface side of the back surface layer 32. In general, the back surface of the back surface layer 32 is provided with openings (reference numerals 23 to 25 in FIG. 2) for assembling various components and ruled lines indicating assembly positions. If the back surface layer 32 is not adhered around such openings and ruled lines, the openings may float or the ruled lines may be difficult to see, which may hinder the assembly of components.

  In this regard, in the third embodiment, the back layer 32 and the adhesion preventing layer 33 can be intentionally bonded even in the non-bonded region B. Therefore, necessary portions of the back surface layer 32 such as the periphery of the opening and the ruled line can be partially adhered, and the parts can be assembled without any trouble. As the adhesive S, it is desirable to select a liquid moisture curable adhesive or a thermosetting resin adhesive that easily penetrates into the adhesion preventing layer 33.

Here, a preferable mass of the adhesion preventing layer 33 will be described.
In order to allow the adhesive S to exude satisfactorily when the adhesion preventing layer 33 is crushed, the material of the adhesion preventing layer 33 is represented by a breathable material in which the adhesive S easily penetrates, for example, a polyester spunlace. It is effective to select from various laces, nonwoven fabrics, and porous materials such as slab urethane. Further, in order to obtain membrane vibration, it is necessary for sound to enter the membrane vibration generating layer. In this respect as well, the material constituting the adhesion preventing layer 33 is preferably a breathable material. However, if the mass of the adhesion preventing layer 33 is set too small with respect to the adhesive S on the back surface of the back surface side fiber layer 28, the adhesive S oozes out on the back surface of the adhesion preventing layer 33 in the non-adhesion region B. There is a possibility that the membrane vibration cannot be obtained.

  On the other hand, if the mass of the adhesion preventing layer 33 is set too large, the adhesive S does not ooze out to the back surface 33a of the crushed portion, and the non-adhesive region B cannot be partially adhered. Accordingly, the adhesive S is prevented from oozing out in the portion where the adhesion preventing layer 33 is not crushed, and the adhesion prevention is performed according to the application amount of the adhesive S so that the adhesive S oozes out in the portion where the adhesion preventing layer 33 is crushed. It is preferable to set the mass of the layer 33.

Therefore, the present inventors investigated a suitable mass per unit area of the adhesion preventing layer 33. As a result of the investigation, when the mass of the adhesion preventing layer 33 is m1, and the mass of the adhesive S applied to the back surface of the back surface side fiber layer 28 is m2, (m1-m2) is 15 (g / m ² ) or less. If the adhesive prevention layer 33 is not crushed, the adhesive S oozes out, and if (m1-m2) is 35 (g / m ² ) or more, the adhesive even if the adhesion prevention layer 33 is crushed. It turns out that S does not ooze out. That is, if (m1-m2) is set from the range of 15 to 35 (g / m ² ), the portion where the adhesion preventing layer 33 is not crushed is prevented from seeping out the adhesive S, and the adhesion preventing layer 33 is crushed. It was found that the adhesive S oozes out in the part. For example, using an isocyanate in the adhesive S, the case of using a spun lace anti-adhesion layer 33, with respect to the mass of the isocyanate 15~19 (g / ^{m 2),} the mass of spun lace 30~50 (g / ^{m 2} ) Is preferable.

(Fourth embodiment)
Next, 4th Embodiment concerning this invention is described based on FIG. 9 and FIG.
As shown in FIG. 9, the vehicle ceiling material 20 </ b> A according to the fourth embodiment has wire harnesses 45 and 46 fixed to the back surface of the back surface layer 32, and the wire harnesses 45 and 46 are passed through the recess 44 </ b> A. It is a groove fixed. The wire harness 45 is connected to a room lamp 47 provided at the center of the curved portion 22 and a map lamp 48 provided at the center of the front portion 21. The wire harness 46 is wired so as to extend rearward along the side edge of the bending portion 22 from the side end of the front portion 21 and then to extend in the vehicle width direction on the rear side of the bending portion 22. Connected to etc. The wire harnesses 45 and 46 are passed through the recess 44A provided on the wiring path, and are fixed to the inner surface (bottom surface or side surface) of the recess 44A by the heat-resistant tape 49.

A method for manufacturing the vehicle ceiling material 20A for forming such a recess 44A will be described with reference to FIG.
As shown in FIG. 10A, in the basic configuration of the third embodiment, the width of the convex portion 43A of the lower mold 42 is set larger than the outer diameter of the wire harness, and the height of the convex portion 43A is set to, for example, a wire. Set to the same or larger than the outer diameter of the harness. Using such a convex portion 43A, as shown in FIG. 10B, the concave portion 44A is formed deeply until the base material 26 is recessed. At this time, as shown by the arrow in the figure, the adhesive prevention layer 33 is crushed so that the adhesive S oozes out to the back surface 33a of the adhesion prevention layer 33, and this oozing out adhesive S prevents adhesion of the recess 44A. Adhere to layer 33.

  Then, as shown in FIG. 10C, after the wire harnesses 45, 46 are passed through the formed recess 44A, the wire harnesses 45, 46 are fixed to the bottom surface of the recess 44A with a heat-resistant tape 49.

  Suppose that the wire harnesses 45 and 46 are fixed without providing the recess 44A. In this case, since the wire harnesses 45 and 46 are fixed to the floating back layer 32, it is difficult to stably fix the wire harnesses 45 and 46. For this reason, when vibration is applied to the ceiling member 20, the wire harnesses 45 and 46 move, and problems such as abnormal noise occur. Further, the aluminum vapor deposition layer constituting the back layer 32 may be rubbed and damaged by the movement of the wire harnesses 45 and 46.

  In this respect, in the fourth embodiment, the wire harnesses 45 and 46 can be stably fixed to the recess 44A firmly bonded to the adhesion preventing layer 33. There is no fear of moving and generating abnormal noise or damaging the aluminum deposition layer.

  Also in the fourth embodiment, since the concave portion 44A is adhered to the adhesion preventing layer 33 with the adhesive S that has exuded from the adhesion preventing layer 33, the material and suitable mass of the adhesion preventing layer 33 are the same as those in the third embodiment. The configuration is the same as in FIG.

  As mentioned above, although this invention was demonstrated using embodiment, it cannot be overemphasized that the technical scope of this invention is not limited to the range as described in the said embodiment. It will be apparent to those skilled in the art that various modifications or improvements can be added to the above-described embodiments. Further, it is apparent from the scope of the claims that the embodiments added with such changes or improvements can be included in the technical scope of the present invention.

  For example, in the embodiment, the region including both ends in the vehicle width direction in the back surface layer is set as the adhesion region, but the vehicle in the vehicle length direction of the adhesion preventing layer is set to be shorter than the length of the fiber layer, and the vehicle in the back surface layer is set. The front and rear regions including both ends in the length direction may be used as the bonding region.

DESCRIPTION OF SYMBOLS 10 Vehicle 14 Cabin 20 Vehicle ceiling material 20A Vehicle ceiling material 26 Base material 28 Back surface side fiber layer (fiber layer)
31 Skin layer 32 Back surface layer 33 Adhesion prevention layer 33a Back surface 34 Adhesion prevention layer 44 Recess 44A Recess A Adhesion area A1 Adhesion area A2 Adhesion area B Non-adhesion area B1 Non-adhesion area S Adhesive

Claims (1)

A base material, a skin layer provided on the front surface side of the base material and forming a ceiling surface in a vehicle interior, a reinforcing fiber layer provided on the back surface side of the base material, and attached to the back surface of the fiber layer In a vehicle ceiling material having an adhesive and a back surface layer for venting bonded to the fiber layer by the adhesive,
Between the fiber layer and the back layer, having an adhesion prevention layer narrower than the back layer,
The back surface layer is provided with a recess that dents the base material side and crushes the adhesion preventing layer to ooze out the adhesive on the back surface of the adhesion preventing layer.
A ceiling material for a vehicle, wherein the concave portion and the adhesion preventing layer are bonded with the oozing adhesive.

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