JP7216404B2 - Molded ceiling material for vehicle and manufacturing method thereof - Google Patents

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a molded vehicle ceiling material arranged on the interior side of a roof panel of a vehicle, and a method of manufacturing the same.

As a molded ceiling material for a vehicle, for example, a hard urethane or the like is used as a base material layer, glass fiber reinforcing layers are provided on both sides, and a skin layer and a back layer are provided on the outside of each of the glass fiber reinforcing layers. commonly known. The glass fiber reinforcing layer is composed of a glass mat or the like, and the glass mat or the like is coated with an adhesive made of a urethane-based resin (for example, an isocyanate-based resin). In addition to reinforcing the base material layer and maintaining the shape after molding, the adhesive applied to each glass fiber reinforced layer is used to bond between the skin layer and the glass fiber reinforced layer, and between the back layer and the glass. The fiber reinforced layers are joined together to obtain the required bonding strength between the layers. The skin layer is composed of a non-woven fabric, a laminated skin of tricot or slab urethane, a woven fabric, a knitted fabric, a plastic sheet, or the like.

In recent years, roof panels have become thinner in order to reduce weight, and many parts such as wire harnesses are attached to the back side of the molded ceiling material for the purpose of modularizing vehicle interior parts. The roof panel tends to vibrate while the vehicle is running, and the sound of rain or the like tends to be transmitted into the passenger compartment. Therefore, various measures have been taken to improve the soundproof performance (sound absorption performance, sound insulation performance) in the passenger compartment. For example, the molded ceiling material for a vehicle of Patent Document 1 includes a ceiling material body facing the interior of the vehicle, and the ceiling material body includes a base material layer made of a rigid urethane foam and a The first glass fiber reinforced layer provided, the second glass fiber reinforced layer provided on the roof panel side of the base layer, and the interior surface of the vehicle interior provided on the interior side of the first glass fiber reinforced layer and the epidermis layer. On the roof panel side of the second glass fiber reinforced layer, a slab urethane layer with high sound absorption performance, a resin film layer with high impermeability, and a back layer made of non-woven fabric are provided in order to improve soundproofing. It has a structure in which they are provided in order from the fiber reinforcement layer side.

In addition, in the molded ceiling material for vehicles as described above, it is required not only to improve the soundproofing performance but also to improve the heat insulation performance (heat shielding performance) to suppress the temperature rise in the vehicle interior due to sunlight etc. at a high level. .

JP 2016-203944 A

In Patent Document 1, since the slab urethane layer is provided on the entire surface of the roof panel side of the ceiling material main body, the soundproofing performance and heat insulation performance are dramatically improved compared to those without the slab urethane layer. had predicted. However, in the construction as described above, contrary to expectations, the sound absorption performance and the heat insulation performance were only slightly improved compared to the conventional product, and the expected sound insulation performance and heat insulation performance could not be obtained.

Therefore, researchers conducted further research to improve the sound insulation performance and thermal insulation performance of molded ceiling materials, respectively. As one of the countermeasures, the thickness of the slab urethane layer in the molded ceiling material of Patent Document 1 was doubled from 3 mm to 6 mm, and the soundproofing performance and heat insulating performance were evaluated. At this time, the space between the molding surface of the upper mold and the molding surface of the lower mold in the molding mold for molding the molded ceiling material, the so-called clearance of the molding mold, was changed from the conventional thin slab urethane layer molding. When molding a molded ceiling material with a thicker slab urethane layer with the same settings as when molding the ceiling material, a large amount of the adhesive applied to the glass fiber reinforcing layer permeates the slab urethane layer. It was found that the slab urethane layer was not restored to its original thickness after molding. Therefore, by setting the gap between the molding surface of the upper mold and the molding surface of the lower mold wider than before, even if the adhesive permeates the slab urethane layer during molding, the slab urethane layer will not be removed after molding. I decided to mold the molded ceiling material in an adjusted state so that it can be restored to its original thickness. As a result, the soundproofing performance and heat insulation performance of the molded ceiling material were greatly improved, but on the other hand, a new problem arose. That is, if the distance between the molding surface of the upper mold and the molding surface of the lower mold is set wider than before so that the slab urethane layer with increased thickness can be restored to its original thickness after molding, When the molding die is closed and the slab urethane layer is compressed, the pressure applied to the slab urethane layer becomes insufficient. and the glass fiber reinforced layer. Therefore, it has been found that the skin layer of the molded ceiling material sagging down does not make it a product, and that the molded ceiling material cannot be maintained in a desired shape and strength.

In order to avoid this, it is conceivable to increase the amount of adhesive applied to the glass fiber reinforcing layer, but in that case, the adhesive will not seep out on the surface of the skin layer that is visible to the occupants inside the vehicle. There is a limit to increasing the adhesive applied to the glass fiber reinforcing layer on the skin layer side. Therefore, it is desirable not to increase the amount of adhesive applied to the glass fiber reinforced layer on the skin layer side. At the same time, an attempt was made to increase the amount of adhesive applied to the glass fiber reinforcing layer on the back layer side.

In this case, simply increasing the amount of adhesive applied to the glass fiber reinforced layer on the back layer side will solve the lack of adhesion between the layers on the back side of the molded ceiling material, but the increased adhesive will not affect the glass fiber during molding. A large amount of it permeates from the reinforcing layer to the slab urethane layer, which causes a problem that the slab urethane layer cannot be restored to its original thickness after molding. Therefore, as a countermeasure, an attempt was made to provide a non-woven fabric layer between the glass fiber reinforcing layer and the slab urethane layer.

When a non-woven fabric layer is provided between the glass fiber reinforced layer and the slab urethane layer, the nonwoven fabric layer is applied to the glass fiber reinforced layer in the so-called general surface area, excluding the mounting surface (reference surface) of the ceiling material body with the vehicle body. Since the penetration of the adhesive into the slab urethane layer is blocked by the non-woven fabric layer, the slab urethane layer can be restored to its original thickness after molding. , the slab urethane layer is strongly crushed and the adhesive applied to the glass fiber reinforced layer passes through the non-woven fabric layer and penetrates into the slab urethane layer, resulting in a compressed state of the slab urethane layer. found to harden. However, this measure alone did not solve the general problem of insufficient strength and shape retention of molded ceiling materials, as well as insufficient adhesion between layers.

Specifically, increasing the amount of adhesive applied to the fiberglass reinforcing layer or decreasing the density of the nonwoven fabric layer increases the adhesion between the layers and achieves the desired strength on the general surface of the molded ceiling material. However, the restoring force of the slab urethane layer is insufficient, and the desired soundproofing performance and heat insulating performance cannot be obtained. When the density of the ceiling material is increased, the adhesive strength between the layers becomes insufficient, and the general surface of the molded ceiling material cannot be obtained with the desired strength, and the shape retention becomes difficult.

The present invention has been made in view of such points, and its object is to have high soundproof performance and heat insulation performance, to increase the adhesive strength between each layer during molding, and to achieve the desired performance during molding. The object of the present invention is to provide a molded ceiling material for a vehicle and a method for manufacturing the same, which can ensure the shape and strength of the vehicle.

In order to achieve the above object, a molded ceiling material is obtained by providing a plurality of areas to which two different pressures are applied in the thickness direction of the ceiling material body when molding the molded ceiling material. Characterized by

Specifically, in a method for manufacturing a molded ceiling material for a vehicle having a panel-shaped ceiling material main body disposed on the interior side of the roof panel of the vehicle, the following solutions were taken.

That is, in the first invention, the ceiling material main body is formed by curing a substrate layer made of a rigid urethane foam and a first adhesive applied, and is provided on the vehicle interior side of the substrate layer. a second glass fiber reinforcing layer formed by curing the applied second adhesive and provided on the roof panel side of the base material layer; and the first glass fiber A skin layer that is bonded to the vehicle interior side of the reinforcing layer using the first adhesive and becomes an interior surface of the vehicle interior, and the second adhesive is applied to the roof panel side of the second glass fiber reinforcement layer. a nonwoven fabric layer provided on the roof panel side of the second glass fiber reinforced layer; and a nonwoven fabric layer provided on the roof panel side of the second glass fiber reinforced layer. and a film layer provided on the roof panel side of the slab urethane layer, and the surface of the soundproof and heat insulation reinforcing layer facing the roof panel has a dotted or linear shape in plan view A manufacturing method for manufacturing a molded ceiling material for a vehicle, which is provided with a plurality of recesses and a plurality of protrusions located between the adjacent recesses and projecting toward the roof panel, the method comprising: a mold; It has an upper mold and a lower mold that face each other and are set to a mold clearance corresponding to the thickness of the material of the slab urethane layer when closed, and a plurality of dotted or linear projections on the molding surface of the lower mold. is provided, prepare a molding die in which a plurality of narrow parts and wide parts occur in the mold clearance, and stack each material of the film layer, the slab urethane layer, and the nonwoven fabric layer in order in advance. The material for the soundproof and heat insulation reinforcing layer in a state of being integrally joined is set on the molding surface of the lower mold so that the material side of the film layer faces downward. The material of the second glass fiber reinforced layer coated with adhesive, the material of the base layer, the material of the first glass fiber reinforced layer coated with the first adhesive, and the material of the skin layer are stacked in this order. After that, the molding die is closed and the molding surface of the upper mold is pressed against the laminate, so that the laminate is formed by the molding surface of the upper mold and the lower mold. While deforming along the surface, the slab urethane layer is pressed against the nonwoven fabric layer side with a first pressure in the region where the mold clearance is narrowed by the protrusions to apply the second adhesive. It is permeated into the slab urethane layer through the nonwoven fabric layer and cured by high pressure molding. While obtaining the shaped portion, the slab urethane layer is pushed toward the nonwoven fabric layer side in the area where the mold clearance is wide by the portion of the lower mold that does not have the protrusions, and a second pressure that is smaller than the first pressure is applied. Pressing with pressure causes the second adhesive to penetrate into the second glass fiber reinforced layer side of the nonwoven fabric layer and harden to obtain a low pressure molded part, while the base material is applied to the upper mold side of the laminate. A pressure close to the first pressurizing force is applied over the entire area under the influence of the pressure of each projecting portion through the above, so that the first adhesive is applied to the first glass fiber reinforcing layer side over the entire surface layer. By penetrating and curing, the recesses are formed at positions corresponding to the protrusions, and the protrusions are formed at positions corresponding to the portions of the lower mold where there are no protrusions. A ceiling material body is obtained .

A second invention is characterized in that, in the first invention, the respective recesses are provided so as to form a grid pattern in a plan view.

In a third invention, in the first or second invention, the film layer comprises an aluminum thin film layer provided on the roof panel side and a resin film layer provided on the roof panel side of the aluminum thin film layer. characterized by consisting of

In the first invention, since the regions corresponding to the projections in the slab urethane layer are restored to the original thickness or a thickness close to it, the slab urethane layer with increased thickness is used as a molded ceiling material for vehicles. The soundproof performance and heat insulation performance of can be improved. In addition, since the roof panel has a plurality of recesses and has a plurality of protrusions projecting toward the roof panel between adjacent recesses, the surface area of the soundproof and heat insulation reinforcing layer facing the roof panel is flat compared to the case where the surface area is flat. get wider. Therefore, the amount of sound absorbed by the film vibration of the resin film layer is increased, and the soundproofing performance of the molded vehicle ceiling material can be enhanced. In addition, by providing a plurality of projecting parts on the lower mold of the molding die, narrow parts and wide parts of the mold clearance are set in the molding die, respectively. Due to the first pressure applied in the thickness direction of the ceiling material body in the portion where the clearance is narrow, the amount of the second adhesive that permeates and hardens between the soundproof and heat insulating reinforcing layer and the second glass fiber reinforced layer in that portion becomes relative. will increase substantially. Therefore, the soundproof and heat insulating reinforcing layer and the second glass fiber reinforcing layer are firmly connected to each other, and the adhesive force between the layers can be enhanced. In addition, the interior side of the ceiling material main body is affected by the pressing force of each projecting portion formed on the lower mold through the base material made of hard urethane having rigidity during molding, so the mold clearance extends over the entire area. It narrows down to the same state as when it was molded, and a pressure close to the first pressurizing force is applied over the entire area, resulting in a molded one. Therefore, without significantly increasing the amount of the first adhesive applied to the first glass fiber reinforced layer, the first adhesive can be permeated into the first glass fiber reinforced layer side of the skin layer to obtain sufficient adhesive strength. can. In this manner, not only the strength and shape retention of the ceiling material main body during molding, but also the adhesive strength of the skin layer can be sufficiently ensured.

In the second aspect of the invention, the surface area of the molded vehicle ceiling material is increased over substantially the entire area on the roof panel side, so that the soundproofing performance in the vehicle interior can be uniformly improved.

In the third invention, the heat entering the passenger compartment through the roof panel is reflected by the highly reflective aluminum thin film layer. At that time, heat is generated by far-infrared rays in the resin film layer located on the outermost layer of the molded ceiling material for vehicles, but the heat is transferred to the vehicle interior by the slab urethane layer with high heat insulation performance provided continuously to the aluminum thin film layer. will be efficiently blocked. Therefore, it is possible to provide a molded vehicle ceiling material having high heat insulating performance. In addition, since the resin film layer is positioned as the outermost layer on the roof panel side of the molded vehicle ceiling material, the aluminum thin film layer is not exposed in the space between the roof panel and the molded vehicle ceiling material in an exposed state. . Therefore, even if the space between the roof panel and the molded vehicle ceiling material becomes hot and humid, whitening of the aluminum thin film layer will not occur, and deterioration of heat insulation due to deterioration over time will occur. It can be a molded vehicle headliner that is difficult to install.

1 is a perspective view of a vehicle with a molded vehicle headliner according to an embodiment of the present invention; FIG. FIG. 2 is an enlarged perspective view of part II of FIG. 1 ; FIG. 3 is a cross-sectional view taken along line III-III of FIG. 2; It is a schematic sectional drawing which shows the state just before shape|molding the ceiling material main body with a molding die. 5 is a view in the direction of arrow V in FIG. 4. FIG. FIG. 10 is a table showing the results of examining the peel strength of each sample material obtained by changing each layer constituting the molded ceiling material for a vehicle and molding conditions. FIG. Fig. 10 is a graph showing the results of investigating whether or not the vehicle ceiling material molded while changing the basis weight of the non-woven fabric layer and the amount of adhesive applied to the glass fiber reinforced layer is satisfactory as a product. . It is a graph which evaluated the soundproofing performance about sample material (alpha) and (beta). FIG. 2 is a schematic front view of a heat insulation property evaluation device used when evaluating heat insulation performance. It is the graph which evaluated the heat insulation performance about sample material (alpha) and (beta). It is a graph which evaluated the heat insulation performance about sample material (alpha) and (gamma).

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, embodiments of the present invention will be described in detail based on the drawings. It should be noted that the following description of preferred embodiments is merely exemplary in nature.

FIG. 1 shows a vehicle 10 with a molded vehicle headliner 1 according to an embodiment of the invention. The molded vehicle ceiling material 1 is disposed on the interior side of a roof panel 10a of a vehicle 10 and includes a panel-shaped ceiling material main body 1a.

The ceiling material main body 1a includes a first ceiling portion 1b having a flat shape and second ceiling portions 1c continuously provided on both sides of the first ceiling portion 1b in the vehicle width direction.

The second ceiling portion 1c has a shape that gradually slopes downward as it separates from the first ceiling portion 1b, and serves as an attachment surface to the vehicle body 10b.

As shown in FIGS. 2 and 3, the ceiling material body 1a includes a base layer 2 made of hard urethane foam, a first glass fiber reinforcing layer 3 provided on the inner side of the base layer 2 in the passenger compartment, A second glass fiber reinforcing layer 4 provided on the roof panel 10a side of the base material layer 2, a skin layer 5 made of non-woven fabric provided on the interior side of the first glass fiber reinforcing layer 3, and the second glass fiber reinforcing and a soundproof and heat insulating reinforcing layer 9 provided on the roof panel 10a side of the layer 4. - 特許庁

The rigid urethane foam of the base material layer 2 has a density of 0.022 to 0.035 g/cm ³ and a thickness of 6 to 15 mm.

The first glass fiber reinforcing layer 3 is formed by curing the applied first adhesive 3a made of urethane-based resin. It is intended to be bonded to layer 2 .

The second glass fiber reinforcing layer 4 is formed by curing the applied second adhesive 4a made of urethane-based resin. It is intended to be bonded to layer 2 .

The skin layer 5 serves as an interior surface of the vehicle interior, and is joined to the first glass fiber reinforced layer 3 by the first adhesive 3a that permeates the skin layer 5 from the first glass fiber reinforced layer 3. there is

The soundproof and heat insulating reinforcing layer 9 is joined to the second glass fiber reinforcing layer 4 by the second adhesive 4 a that permeates from the second glass fiber reinforcing layer 4 to the sound insulating and heat insulating reinforcing layer 9 .

The soundproof and heat insulating reinforcing layer 9 is composed of a nonwoven fabric layer 6 provided on the roof panel 10a side of the second glass fiber reinforcing layer 4, a slab urethane layer 7 provided on the roof panel 10a side of the nonwoven fabric layer 6, and the slab urethane. and a film layer 8 provided on the roof panel 10a side of the layer 7 . In addition, in FIG. 3, the thickness of the film layer 8 is exaggerated for convenience.

The nonwoven fabric layer 6 has a basis weight of 60 to 140 g/m ² .

The slab urethane layer 7 has a thickness of 6 to 10 mm, a density of 0.020 to 0.040 g/cm ³ and an air permeability of 10 to 50 cc/cm ² ·s.

The film layer 8 includes an aluminum thin film layer 8a provided on the roof panel 10a side of the slab urethane layer 7, and a resin film layer 8b provided on the roof panel 10a side of the aluminum thin film layer 8a.

The aluminum thin film layer 8a is formed by depositing an aluminum alloy material on the entire interior side of the resin film layer 8b by vapor deposition. That is, the aluminum thin film layer 8a is a deposited layer of an aluminum alloy material.

The resin film layer 8b is made of polyethylene resin, and is the outermost layer of the molded vehicle ceiling material 1 on the side of the roof panel 10a.

The first ceiling portion 1b of the ceiling material main body 1a is a region where the mold clearance C1 is narrowly set by each projecting portion 12a provided on the lower mold 11B of the molding mold 11 to be described later, and the thickness of the ceiling material main body 1a at the time of molding is reduced. A first pressure applied in the direction (hereinafter referred to as first pressure P1) causes the second adhesive 4a to permeate the slab urethane layer 7 through the nonwoven fabric layer 6 and harden to form a plurality of high pressure adhesives. In addition to obtaining the molding portion 9A, a first pressing force P1 applied in the thickness direction of the ceiling material main body 1a during molding in a region where the mold clearance C1 is set wide by a portion of the lower mold 11B, which will be described later, without the protrusions 12a. A second pressure (hereinafter referred to as a second pressure P2) smaller than the second adhesive 4a penetrates into the second glass fiber reinforcing layer 4 side of the nonwoven fabric layer 6 and hardens to form a plurality of low pressures. While the molded portion 9B is obtained, the interior side of the first ceiling portion 1b is affected by pressing of each protruding portion 12a of the molding die 11 to be described later through the base layer 2 made of hard urethane during molding. , the mold clearance C1 is narrowed over substantially the entire area to obtain the same state as when molding is performed. It is obtained by penetrating into the first glass fiber reinforcing layer 3 and curing.

That is, a large number of grooves 9b (recesses) linearly extending in the vehicle front-rear direction and vehicle width direction are formed at positions corresponding to the respective high pressure formed portions 9A on the surface 9a facing the roof panel of the soundproof and heat insulation reinforcing layer 9. Each of the grooves 9b has a lattice shape when viewed from above.

In addition, the portions of the roof panel facing surface 9a surrounded by the recessed grooves 9b, that is, the positions of the roof panel facing surface 9a corresponding to the low-pressure formed portions 9B are provided with gentle grooves that protrude toward the roof panel 10a. A curved convex surface 9c (convex portion) is formed.

The second ceiling portion 1c of the ceiling material main body 1a is pressed against the slab by a third pressure (hereinafter referred to as third pressure P3) greater than the first pressure P1 applied in the thickness direction of the ceiling material main body 1a during molding. While the urethane layer 7 is compressed and deformed toward the nonwoven fabric layer 6 , the second adhesive 4 a is permeated into the slab urethane layer 7 through the nonwoven fabric layer 6 and hardened, and the first adhesive 3 a is applied to the first adhesive layer 5 of the skin layer 5 . It has an extremely thin shape formed by penetrating into the glass fiber reinforcing layer 3 and hardening.

Next, a method for manufacturing the molded vehicle ceiling material 1 according to the embodiment of the present invention will be described in detail.

As shown in FIGS. 4 and 5, the ceiling material main body 1a of the vehicle ceiling material 1 is molded using a molding die 11 having an upper mold 11A and a lower mold 11B facing each other. .

When the molding die 11 is closed, the gap between the upper molding surface 11a of the upper mold 11A and the lower molding surface 11b of the lower mold 11B, the so-called clearance C1 of the molding die 11, is the same as the slab urethane layer 7. It is set to 10.5 to 12.5 mm so as to correspond to the thickness of the material.

A high pressure processed portion 12 is provided in a portion of the lower forming surface 11b where the first ceiling portion 1b of the ceiling material body 1a is formed.

The high-pressure processed portion 12 has a plurality of protrusions 12a that protrude upward and linearly extend along the lower molding surface 11b, and each protrusion 12a extends in a grid pattern in a plan view. .

That is, the molding die 11 is provided with a plurality of linear protrusions 12a on the lower molding surface 11b of the lower die 11B, so that the die clearance C1 has a plurality of narrow portions and wide portions. there is

One partitioned portion surrounded by the protruding portions 12a of the high pressure processed portion 12 has a square shape in plan view.

One partitioned portion surrounded by the protruding portions 12a of the high pressure processed portion 12 has a square shape with a side of 20 mm to 100 mm in plan view. In addition, one partitioned portion surrounded by the protruding portions 12a of the high pressure processed portion 12 may not have a square shape in a plan view, and may have a rectangular shape. In addition, it is not essential that each projection 12a of the high-pressure processed portion 12 extends in a lattice shape in plan view. It may have a shape in which a plurality of circular portions are arranged side by side.

First, a film material is prepared, and an aluminum alloy material is vapor-deposited on one surface of the film material to prepare a material for the film layer 8 consisting of the aluminum thin film layer 8a and the resin film layer 8b.

Next, a material for the slab urethane layer 7 and a material for the nonwoven fabric layer 6 are prepared. The material of the urethane layer 7 and the material of the film layer 8 are laminated in order, and the three sheet materials are integrated by frame lamination to prepare the material of the soundproof and heat insulating reinforcing layer 9 in advance.

Next, after setting the material of the soundproof and heat insulating layer 9 on the lower molding surface 11b of the lower mold 11B so that the material side of the film layer 8 faces downward, the second adhesive 4a is applied on the material of the soundproof and heat insulating layer 9. The material of the second glass fiber reinforcing layer 4 coated with , the material of the base layer 2, the material of the first glass fiber reinforcing layer 3 coated with the first adhesive 3a, and the material of the skin layer 5 are laminated in order. form the body 13;

After that, the molding die 11 is closed and the upper molding surface 11 a of the upper mold 11 A is pressed against the laminate 13 . Then, the molding die 11 deforms the layered body 13 along the upper molding surface 11a of the upper mold 11A and the lower molding surface 11b of the lower mold 11B to form the first ceiling portion 1b. , the slab urethane layer 7 is pressed against the nonwoven fabric layer 6 with a first pressure P1 in the region where the mold clearance C1 is narrowed by the projecting portions 12a, and the second adhesive 4a is applied through the nonwoven fabric layer 6. is permeated into the slab urethane layer 7 and hardened to form a plurality of high pressure molded portions 9A. At this time, the slab urethane layer 7 is maintained in a state of being compressed and deformed so as to form a concave shape toward the nonwoven fabric layer 6 side. On the other hand, in the region of the laminate 13 that molds the first ceiling portion 1b, the molding die 11 moves the slab urethane layer 7 in the region where the die clearance C1 is widened by the portion of the lower die 11B that does not have the projecting portions 12a. is pressed against the nonwoven fabric layer 6 with a second pressure P2 to permeate the second adhesive 4a into the second glass fiber reinforcing layer 4 side of the nonwoven fabric layer 6 and harden to form a plurality of low pressure molded parts 9B. . At this time, the low-pressure molded portion 9B of the slab urethane layer 7 is restored after compressive deformation. On the other hand, the upper mold 11A side of the laminate 13 that forms the first ceiling portion 1b is affected by the pressing force of the protruding portions 12a through the base material layer 2, and a pressure close to the first pressure is applied over the entire area. By being applied, the first adhesive 3a is permeated to the first glass fiber reinforcing layer 3 side of the entire skin layer 5 and hardened. Then, the molding die 11 is deformed along the upper molding surface 11a of the upper mold 11A and the lower molding surface 11b of the lower mold 11B in the region of the laminate 13 for molding the second ceiling portion 1c. The slab urethane layer 7 is pressed toward the nonwoven fabric layer 6 at a portion of the lower die 11B where there is no projecting portion 12a and in a region where the mold clearance C1 is set narrower with a third pressure P3 larger than the first pressure P1. The second adhesive 4a is permeated into the slab urethane layer 7 through the nonwoven fabric layer 6 and cured, and the first adhesive 3a is permeated to the first glass fiber reinforcing layer 3 side of the skin layer 5 and cured. The ceiling material main body 1a is obtained in an extremely thin shape.

Here, the results of examination of the manufacturing conditions of the molded vehicle ceiling material 1 according to the embodiment of the present invention will be described.

(a) Structure of molding die 11 a. Experiment FIG. 6 shows that the first adhesive 3a is applied to the first glass fiber reinforcing layer 3 in such an amount that the first adhesive 3a does not seep out onto the surface of the skin layer 5 when molding the ceiling material body 1a, and the slab The thickness t of the urethane layer 7, the clearance C1 of the molding die 11, the protrusion height h1 of the protrusions 12a, the shape S1 of one partitioned portion surrounded by each protrusion 12a of the high pressure processed portion 12 and the number N1 thereof, While changing the application amount of the second adhesive 4a applied to the second glass fiber reinforcing layer 4, the sample materials A to H of the ceiling material main body 1a were molded, and the skin layer 5 and the first glass in the sample materials A to H were obtained. The adhesive strength between the fiber reinforced layer 3 and between the first glass fiber reinforced layer 3 and the substrate layer 2 was measured to confirm whether or not the minimum required peel strength was obtained. Incidentally, the minimum required peel strength was set with reference to, for example, a value used as a standard value by an automobile manufacturer or the like.

The sample material A has the same structure as a conventional molded ceiling material for vehicles without the slab urethane layer 7, and was molded by setting the clearance C1 of the molding die 11 to 7 mm. .

On the other hand, the sample material B has the same structure as the molded ceiling material 1 for vehicles having the slab urethane layer 7 on the roof panel 10a side, but is molded by the molding die 11 which does not have the projecting portion 12a. is. That is, the first pressure P1 is not applied to the slab urethane layer 7 of the sample material B by the projecting portion 12a during molding.

Furthermore, the sample materials C to H have the same structure as the molded ceiling material 1 for a vehicle of the present invention, and are molded with a molding die 11 having a projecting portion 12a. That is, the first pressure P1 is applied to the slab urethane layer 7 of the sample materials C to H by the projecting portion 12a during molding.

Comparing the sample materials A and B, when the slab urethane layer 7 is provided on the molded ceiling material 1 for a vehicle, the slab urethane layer 7 is restored to its original shape when the molding die 11 is opened after molding. Even if the ceiling material main body 1a is molded by simply setting the clearance C1 of the molding die 11 wide, the space between the skin layer 5 and the first glass fiber reinforcing layer 3, and between the first glass fiber reinforcing layer 3 and the base material It was found that the required peel strength between layer 2 could not be obtained.

On the other hand, looking at the sample materials C to H, when the slab urethane layer 7 is provided in the molded ceiling material 1 for a vehicle, the slab urethane layer 7 restores its original shape when the molding die 11 is opened after molding. When the clearance C1 of the molding die 11 is set wide as described above, and the projections 12a are provided on the molding die 11 to form the ceiling material main body 1a, if each condition is appropriately set, the skin layer 5 and the first It was found that the required peel strength can be obtained between the glass fiber reinforcing layer 3 and between the first glass fiber reinforcing layer 3 and the substrate layer 2 .

stomach. Protrusions 12a a. According to the experimental results, under the following conditions, the minimum required adhesive strength between the skin layer 5 and the first glass fiber reinforced layer 3 and between the first glass fiber reinforced layer 3 and the base layer 2 It turned out to be more than that.
・Increase amount g1 of clearance C1 of molding die 11=(thickness t of slab urethane layer 7)×(55±10%)
・Protruding height h1 of the protruding portion 12a=Increase amount g1 of clearance C1×(45 to 95%)
・Shape S1 of the partitioned portion of the high pressure processed portion 12: Square shape, rectangular shape, circular shape, etc. in plan view ・Number N1 of the partitioned portion of the high pressure processed portion 12: 500 mm × 500 mm of the first ceiling portion 1b 25 to 600 pieces in the area (for example, when the shape S1 of the division part is a square shape of 100 mm × 100 mm or a round shape of 100 mm in diameter, 25 division parts are set in the area of 500 mm × 500 mm of the first ceiling part 1b, When the shape S1 of the division part is a square shape of 20 mm × 20 mm or a round shape of 20 mm in diameter, 600 division parts are set in the area of 500 mm × 500 mm of the first ceiling part 1 b)
The width d1 of the projecting portion 12a is preferably set to 2 mm or more in order to provide rigidity that prevents breakage during molding.

Also, the width d1 and the height h1 of each protruding portion 12a may be set to values that are changed according to the set portion of the first ceiling portion 1b.

(b) Application amount of the second adhesive 4a and basis weight of the nonwoven fabric layer 6 Fig. 7 shows that after molding the ceiling material body 1a, the slab urethane layer 7 of the first ceiling part 1b has the original thickness, or The second adhesive 4a can be restored to a state close to the original thickness, and furthermore, the second ceiling portion 1c can be made into a thin shape by curing the slab urethane layer 7 in a state of being compressed and deformed. and the basis weight of the non-woven fabric layer 6 are examined.

The density ρ of the slab urethane layer 7 is 0.02 g/m ³ , 0.03 g/m ³ , and 0.04 g/m ³ , and the thickness t is 6 mm, 8 mm, 10 mm, and 12 mm. The clearance C1 is changed between about 45% to 65% of the thickness t of the slab urethane layer 7 according to the thickness t of each slab urethane layer 7, and the protrusion 12a is formed in a predetermined shape, protrusion height, etc. The state of the ceiling material main body 1a molded while variously changing the application amount of the second adhesive 4a and the basis weight of the nonwoven fabric layer 6 was observed.

7 indicates a product that can maintain the desired shape and strength of the molded vehicle ceiling material 1 and satisfies the conditions of both the first ceiling portion 1b and the second ceiling portion 1c after molding. The △ mark indicates that the shape and strength of the molded vehicle ceiling material 1 and the state of both the first ceiling part 1b and the second ceiling part 1c after molding are not fully satisfactory, but as a product. The x marks indicate those that are valid, and those that are not valid as products.

From the results of FIG. 7, it was found that the application amount of the second adhesive 4a should be set to 25 to 50 g/m ² and the basis weight of the nonwoven fabric layer 6 should be set to 60 to 140 g/m ² .

Here, evaluation results of the soundproofing performance of the molded vehicle ceiling material 1 according to the embodiment of the present invention will be described.

FIG. 8 is a graph in which the horizontal axis is the frequency and the vertical axis is the sound absorption coefficient, showing that the higher the sound absorption coefficient at each frequency, the higher the sound absorption performance. Data B is obtained using a sample material α similar to a general molded ceiling material for vehicles, which is composed of a skin layer 5 made of nonwoven fabric and a base layer 2 made of hard urethane foam having a thickness of 6.5 mm. The data D1 was obtained using the same sample material β as the vehicle ceiling material 1 according to the embodiment of the present invention. The sample material β is a second glass fiber reinforcing layer 4 obtained by applying a second adhesive 4a of 35 g/m ² to the sample material α, a nonwoven fabric layer 6 having a basis weight of 100 g/m ² , and a density ρ of 0.024 g. A slab urethane layer ⁷ with a thickness t of 8 mm and a resin film layer 8b are laminated in this order, the clearance C1 of the molding die 11 is set to 11.5 mm, and the lower molding surface 11b 400 squares of 25 mm x 25 mm were arranged in the shape S1 of the partitioned portion of the high-pressure processed portion 12 provided in , and the protrusion height of each protrusion 12a was set to 3.2 mm.

As shown in Fig. 8, the sample material β has a higher soundproof performance than conventional general molded ceiling materials for vehicles over almost the entire range from low frequencies to high frequencies in the range of 0.5 to 6.3 kHz. I found out. More specifically, the sound absorption coefficient of sample material β was improved by about 60% at 1 kHz, improved by about 35% at 2 kHz, and improved by about 25% at 4 kHz compared to sample material α. .

Thus, it was found that the molded vehicle ceiling material 1 of the embodiment of the present invention has higher soundproofing performance in most frequency ranges than the conventional molded vehicle ceiling material. This is because the slab urethane layer 7 in each low-pressure molded portion 9B of the ceiling material main body 1a has been restored to its original thickness or a thickness close to it, so the slab urethane layer 7 with increased thickness This is considered to be because the soundproofing performance of the molded ceiling material 1 for a vehicle is improved. Further, each high-pressure molded portion 9A is maintained in a state in which the slab urethane layer 7 is compressed and deformed by the first pressure P1, and forms a recessed shape toward the roof panel 10a side, and each low-pressure molded portion 9B. has a convex surface 9c that is gently curved so as to protrude toward the roof panel 10a, so that the surface area of the surface facing the roof panel 10a in the soundproof and heat insulating reinforcing layer 9 is wider than that of a flat one. It is believed that this is because the amount of sound absorbed by membrane vibration has increased, and the soundproofing performance of the molded vehicle ceiling material 1 has improved. As described above, according to the embodiment of the present invention, the high-pressure molded parts 9A and the low-pressure molded parts 9B can enhance the soundproofing performance of the molded ceiling material 1 for vehicles.

Further, since each high-pressure molded portion 9A is formed in the molded vehicle ceiling material 1 so as to have a lattice shape in a plan view, the surface area is increased over substantially the entire area on the side of the roof panel 10a. The vehicle interior can be made evenly quiet.

Next, the evaluation results of the heat insulation performance of the vehicle ceiling material 1 according to the embodiment of the present invention will be described.

First, a heat insulation performance evaluation apparatus 15 as shown in FIG. 9 was prepared for evaluation of heat insulation performance. The heat insulating performance evaluation device 15 is for evaluating the degree of temperature rise in the passenger compartment when the temperature outside the passenger compartment becomes high. A gypsum annular body 17 is provided between the supporting body 16 and the periphery of the upper opening of the supporting body 16 so that the sample material 14 of the molded ceiling material 1 for a vehicle can be sandwiched so that the surface layer 5 side of the sample material 14 faces downward. A heat source plate 18 made of metal is mounted on the annular body 17, and the temperature of the heat source plate 18 is raised using an infrared lamp (not shown).

Then, each sample material 14 was set in the heat insulating performance evaluation device 15, and the temperature rise at the point C in FIG.

FIG. 10 is a graph in which the horizontal axis is the elapsed time from the start of evaluation and the vertical axis is the temperature at point C in the elapsed time. ing. Data B was obtained by setting the sample material α in the heat insulation performance evaluation device 15 and data D2 was obtained by setting the sample material β in the heat insulation performance evaluation device 15 .

Then, as shown in FIG. 10, data B and data D2 began to exhibit a difference in temperature rise immediately after the start of the test, and a difference in temperature rise of about 2.5° C. was observed after 60 minutes had elapsed. It is believed that this is because the slab urethane layer 7, which has a high heat insulating performance, has a thickness, and thus efficiently blocks the heat entering the passenger compartment through the roof panel 10a.

Next, a sample material γ was prepared by adding an aluminum thin film layer 8a between the slab urethane layer 7 and the resin film layer 8b of the sample material β, and the sample material γ was set in the heat insulation performance evaluation device 15 to measure the heat insulation performance. was evaluated.

As shown in FIG. 11, data B was obtained by setting the sample material α in the heat insulation performance evaluation device 15, and data D3 was obtained by setting the sample material γ in the heat insulation performance evaluation device 15. is. In data B and data D3, a temperature difference began to appear immediately after the start of the test, and a temperature difference of about 5.2° C. was observed after 60 minutes had passed. This is presumably because the heat entering the passenger compartment through the roof panel 10a is reflected by the highly reflective aluminum thin film layer 8a. At that time, it is considered that far-infrared heat is generated in the resin film layer 8b located in the outermost layer of the molded vehicle ceiling material 1, but the slab urethane layer 7 with high heat insulation provided continuously to the aluminum thin film layer 8a is considered to efficiently block heat from going into the passenger compartment. Therefore, it was found that the molded ceiling material 1 for a vehicle according to the embodiment of the present invention has a higher heat insulation performance than the conventional molded ceiling material for a general vehicle.

As described above, according to the embodiment of the present invention, by providing the soundproof and heat insulating layer 9 on the roof panel 10a side, the molded ceiling material 1 for a vehicle can have high heat insulating performance.

Further, since the resin film layer 8b is positioned as the outermost layer on the roof panel 10a side of the molded vehicle ceiling material 1, the aluminum thin film layer 8a is exposed in the space between the roof panel 10a and the molded vehicle ceiling material 1. will not be exposed to Therefore, even if the space between the roof panel 10a and the molded vehicle ceiling material 1 is in a high temperature and high humidity state, the aluminum thin film layer 8a will not whiten, and the heat insulating property will deteriorate due to deterioration over time. It is possible to obtain the molded ceiling material 1 for a vehicle in which it is difficult for the occurrence of

As described above, according to the embodiment of the present invention, by providing a plurality of projecting portions 12a on the lower mold 11B of the molding die 11, the molding die 11 is provided with a narrow portion and a wide portion of the mold clearance C1. Therefore, even if the thickness of the slab urethane layer 7 is increased, the first pressure P1 applied in the thickness direction of the ceiling material main body 1a in the portion where the mold clearance C1 is narrow causes the soundproof and heat insulation reinforcing layer 9 and the second glass fiber in the portion to be separated. The amount of the second adhesive 4a that permeates between the reinforcing layer 4 and hardens relatively increases. Therefore, the soundproof and heat insulating reinforcing layer 9 and the second glass fiber reinforcing layer 4 are firmly connected to each other, and the adhesion between the layers can be enhanced.

In addition, since the interior side of the ceiling material body 1a is affected by the pressure of each projecting portion 12a formed on the lower mold 11B through the base layer 2 made of hard urethane having rigidity, the mold clearance C1 is It is narrowed over the entire area and is in the same state as if it had been molded, and is molded by applying a pressure close to the first pressure P1 over the entire area. Therefore, without significantly increasing the amount of the first adhesive 3a to be applied to the first glass fiber reinforced layer 3, the first adhesive 3a is allowed to permeate the first glass fiber reinforced layer 3 side of the skin layer 5 to achieve sufficient adhesion. power can be obtained. Thus, not only the strength and shape retention of the ceiling material main body 1a during molding, but also the adhesive strength of the skin layer 5 can be sufficiently ensured.

In the embodiment of the present invention, each high-pressure molded portion 9A (or recessed groove 9b) is formed in a lattice shape in plan view, but is not limited to this, for example, it is formed in a straight line shape in plan view. It may be formed, or may be formed in a dotted shape.

In addition, in the embodiment of the present invention, a high pressure processing portion 12 for applying the first pressure P1 to the slab urethane layer 7 of the ceiling material main body 1a during molding is formed integrally with the lower molding surface 11b of the lower mold 11B. However, the high-pressure processing unit 12 may be formed by forming a mesh-like member such as a wire mesh separately from the lower mold 11B, for example, and then attaching the member to the lower mold 11B by welding. In this case, the protrusion height h1 of the protrusion 12a must satisfy the condition h1=increase amount g1 of clearance C1×(45 to 95%).

INDUSTRIAL APPLICABILITY The present invention is suitable for a molded vehicle ceiling material provided on the interior side of a roof panel of a vehicle.

1 molded ceiling material for vehicle 1a ceiling material body 2 base material layer 3 first glass fiber reinforcing layer 3a first adhesive 4 second glass fiber reinforcing layer 4a second adhesive 5 skin layer 6 nonwoven fabric layer 7 slab urethane layer 8 film Layer 8a Aluminum thin film layer 8b Resin film layer 9 Soundproof and heat insulating layer 9A High pressure molded part 9B Low pressure molded part 9a Roof panel facing surface 9b Groove (recess)
9c Convex surface (convex part)
10 vehicle 10a roof panel 11 molding die 11A upper mold 11B lower mold 11a upper molding surface 11b lower molding surface 12a projection 13 laminate C1 mold clearance

Claims (3)

Having a panel-shaped ceiling material main body arranged on the interior side of the roof panel of the vehicle,
The ceiling material main body includes a base layer made of rigid urethane foam,
a first glass fiber reinforcing layer formed by curing the applied first adhesive and provided on the vehicle interior side of the base material layer;
a second glass fiber reinforcing layer formed by curing the applied second adhesive and provided on the roof panel side of the base material layer;
A skin layer that is bonded to the vehicle interior side of the first glass fiber reinforcement layer using the first adhesive and that serves as an interior surface of the vehicle interior;
a soundproof and heat insulating reinforcing layer bonded to the roof panel side of the second glass fiber reinforcing layer using the second adhesive,
The soundproof and heat insulating reinforcing layer includes a nonwoven fabric layer provided on the roof panel side of the second glass fiber reinforcing layer;
a slab urethane layer provided on the roof panel side of the nonwoven fabric layer;
a film layer provided on the roof panel side of the slab urethane layer,
On the surface of the soundproof and heat insulating layer facing the roof panel, there are a plurality of recesses that are point-like or linear in a plan view, and a plurality of recesses that are located between the adjacent recesses and project toward the roof panel. A manufacturing method for manufacturing a molded vehicle ceiling material provided with a convex portion, the method comprising:
When the mold is closed, it has an upper mold and a lower mold that face each other and are set to a mold clearance corresponding to the thickness of the material of the slab urethane layer, and a plurality of dot-like or linear protrusions on the molding surface of the lower mold. preparing a molding die in which a plurality of narrow portions and wide portions are generated in the mold clearance by providing a part,
The materials of the film layer, the slab urethane layer, and the non-woven fabric layer are laminated in order and joined integrally in advance, and the material of the soundproof and heat insulation reinforcing layer is placed on the molding surface of the lower mold with the material side of the film layer facing downward. and set
Next, the material of the second glass fiber reinforcing layer, the material of the base material layer, and the first glass fiber coated with the first adhesive are applied on the material of the soundproof and heat insulation reinforcing layer. Forming a laminate by sequentially stacking the material of the reinforcing layer and the material of the skin layer,
Thereafter, the molding die is closed and the molding surface of the upper mold is pressed against the laminate, thereby deforming the laminate along the molding surface of the upper mold and the molding surface of the lower mold. while pressing the slab urethane layer against the nonwoven fabric layer with a first pressure in the region where the mold clearance is narrowed by the protrusions, and the second adhesive is applied through the nonwoven fabric layer. The slab urethane layer is permeated and cured to obtain a high-pressure molded part, and the slab urethane layer is spread over the non-woven fabric layer in the region where the mold clearance is widened by the part of the lower mold without the protrusions. side with a second pressure smaller than the first pressure to allow the second adhesive to penetrate into the second glass fiber reinforced layer side of the nonwoven fabric layer and harden to obtain a low-pressure molded part. A pressure close to the first pressure is applied to the upper mold side of the laminate through the base material under the influence of the pressure of the protrusions over the entire area, so that the first adhesive is applied to the surface. By penetrating into the first glass fiber reinforced layer side of the entire layer and curing, the recesses are formed at positions corresponding to the protrusions, and the portions of the lower mold where there are no protrusions are formed. A method for producing a molded ceiling material for a vehicle, characterized by obtaining the ceiling material main body having the projections formed at corresponding positions . In the method for producing a molded vehicle ceiling material according to claim 1,
A method of manufacturing a molded ceiling material for a vehicle, wherein the recesses are provided so as to form a lattice when viewed from above. In the method for manufacturing a molded ceiling material for a vehicle according to claim 1 or 2,
A method for producing a molded ceiling material for a vehicle, wherein the film layer comprises an aluminum thin film layer provided on the roof panel side, and a resin film layer provided on the roof panel side of the aluminum thin film layer. .

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