JPH05179546A - Molded roof substrate - Google Patents

Abstract

PURPOSE:To obtain a molded roof substrate enabling the lightweight due to reduction in basis weight while maintaining the rigidity. CONSTITUTION:Reinforcing members 21 to 24 of a prescribed width are provided in the front, rear, left and right peripheral parts of a fibrous board material 11. Thereby, reinforcing parts 1 to 4 having higher rigidity than that of the central part 5 are arranged so as to surround the central part. The resultant board material 11, together with surface materials 6 and 7, is then press molded by a press molding machine to afford the objective molded roof substrate 10 of a prescribed shape. Bending and hanging down of the molded roof substrate 10 do not occur in installing the molded roof substrate in a car body roof panel by integrally providing the reinforcing parts 1 to 4 having the increased rigidity in the peripheral parts. Since the rigidity of the whole substrate 10 is enhanced by reinforcing the peripheral parts, the basis weight in the central part 5 of the board material 11 can be reduced to provide the lightweight.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a molded ceiling base material for automobiles.

[0002]

2. Description of the Related Art A molded ceiling base material is one of the interior materials for automobile ceilings, which is formed by laminating a flat board material and a design skin material (and in some cases, a design skin material with a pad material). Is integrally molded into a predetermined shape by a press molding machine. Further, as the board material, there is one using a fibrous material such as a non-woven fabric mainly made of glass fiber or synthetic fiber or a felt material. The molded ceiling base material using this fibrous board material has good moldability and workability in assembling, and is therefore widely applied to mass-produced vehicles.

[0003]

However, since the above-mentioned conventional molded ceiling base material uses a large amount of glass fibers or synthetic fibers, it is heavy and needs to be made lightweight.
Therefore, for example, if the basis weight of the entire board material is reduced, the weight of the entire base material can be reduced. However, if this is done, the rigidity of the entire base material will be reduced and the base material will be easily broken, and it will be mounted on the vehicle body ceiling. There was a risk of bending during work.

In addition, depending on the type of vehicle, there is a type in which the trim member for fixing the front and rear sides of the molded ceiling base material to the vehicle body is omitted to reduce the number of parts. In this case, as described above, when a sheet having a low basis weight of the board material is used for the molded ceiling base material, its rigidity is low, and therefore the front and rear sides of the molded ceiling base material may hang down after mounting on the vehicle body. , Problems such as swinging up and down occur.

Therefore, it is an object of the present invention to provide a molded ceiling base material capable of reducing the weight of the board material and reducing the weight while maintaining the rigidity as a whole. ..

[0006]

In order to solve the above-mentioned problems, the molded ceiling base material according to the present invention is formed by molding a fibrous board material having all peripheral edges reinforced into a predetermined shape. It is a feature. The molded ceiling substrate according to the present invention is an interior material that is mounted on the inner surface of the vehicle body roof panel,
By press molding the board material with the reinforcing member added (generally, it is integrally molded with the design skin material and the design skin material with pad material) using a press molding machine, it is formed into a predetermined shape corresponding to the inner surface shape of the roof panel. It is something.

[0007]

In the molded ceiling base material according to the present invention, since the reinforcing portion is provided on the peripheral portion of the board material, even if the rigidity of the portion other than the peripheral portion of the board material (hereinafter referred to as the central portion) is low. The rigidity of the entire substrate can be increased. Thereby, even if the basis weight of the central portion of the board material is reduced, the board material is not easily bent, and the weight of the entire base material can be reduced.

[0008]

【Example】

(First Embodiment) FIG. 1 shows an external configuration of a molded ceiling base material 10 according to the first embodiment of the present invention. The base material 10 of this embodiment is
As shown in FIG. 2, the reinforcing members 21 to 24 having a predetermined width are provided on the front, rear, left and right peripheral portions of the fibrous board material 11 cut into a rectangular shape.
Which is manufactured by stacking surface materials 6 and 7 (shown in FIGS. 3 and 4) such as polyethylene films on the front and back surfaces, heating and press-molding with a press molding machine, and further trimming. Is. Reinforcing parts 1 to 4 arranged so as to surround the central part 5 on the peripheral part of the base material 10.
Are integrally formed. The front and rear reinforcing portions 1 and 2 are fixed to the front and rear sides of the inner circumference of the vehicle body ceiling by trims, or contacted when there is no trim. It is a part fixed to the left and right sides by side garnish. Further, in FIG. 1, the front surface side is a surface facing the vehicle interior, and the back surface side is a surface facing the vehicle body roof panel.

The board material 11 is obtained by stacking glass fibers and thermoplastic resin fibers, for example, a polyolefin resin film, and heat-sealing or embedding them (in a state of being melted and completely permeated). The left and right reinforcing portions 3 and 4 are made more rigid than the central portion 5 by a reinforcing member 24 shown in FIG. 3 (a sectional view taken along the line AA in FIG. 1). The reinforcing member 24 is the same fiber as the fiber forming the board material 11, that is, glass fiber and thermoplastic fiber. The basis weight of the reinforcing portions 3 and 4 is set to be larger than that of the central portion 5 by previously mixing the reinforcing member 24 in the fibers forming the board material 11. The width of the reinforcing portions 3 and 4 is about 5 to 30 cm.

The front and rear reinforcing parts 1 and 2 are shown in FIG.
The rigidity is increased by the reinforcing member 22 shown in the sectional view taken along the line BB). The reinforcing member 22 is made of a thermoplastic resin and is filled or embedded in the continuous voids between the fibers of the board material 11 by utilizing the fact that the board material 11 is fibrous. As a result, the weight per unit area of the reinforcing portions 1 and 2 is reduced to the central portion 5.
More than that, the constituent resin of the reinforcing portion is entangled with the injected resin, and the rigidity of this portion is improved. The width of the reinforcing portions 1 and 2 is also about 5 to 30 cm.

In the molded ceiling base material 10 of this embodiment having the above-mentioned structure, since the peripheral portions of the molded ceiling base material 10 are reinforced by the reinforcing portions 1 to 4, the basis weight of the central portion 5 of the board material 11 is reduced. At least the rigidity of the substrate 10 as a whole becomes high,
It does not easily bend when the molded base material 10 is attached to the vehicle body ceiling. Further, since the reinforcing portions 1 to 4 retain the rigidity as a whole, the basis weight of the central portion 5 of the board material 11 can be reduced, so that it is possible to reduce the total weight of the base material 10 and the interior. The weight of the material can be reduced.

In the molded ceiling base material 10 of this embodiment, since the reinforcing members 21 to 24 are materials that increase the basis weight of the board material 11 or materials that are injected or embedded, the surface of the board material 11 is reinforced. The members 21 to 24 do not protrude, the surface materials 6 and 7 do not have steps at the boundary line between the reinforcing portions 1 to 4 and the central portion 5, and the color change of the design skin material does not occur. The visual appearance can be improved. (Second Embodiment) Next, a second embodiment according to the present invention will be described. Since the external shape of the molded ceiling base material of this embodiment is the same as that of the first embodiment, FIG. 1 is used instead. The molded ceiling base material of this embodiment is different from that of the first embodiment in the structure of the reinforcing portions 1 to 4. That is, in the molded ceiling base material of the present embodiment, the left and right reinforcing portions 3 and 4 have the board material 11 (shown in FIG. 2) as shown in FIG. 5 (a sectional view taken along the line AA in FIG. 1). The same reinforcing material 25 as the fibrous material that constitutes the board material 11 that is cut into a strip having a width of 5 to 30 cm is laminated on the edge portion 15 (which is the same as the one). Also, the front and rear reinforcements 1,
As shown in FIG. 6 (a cross-sectional view taken along the line BB in FIG. 1), 2 is a thermoplastic resin film such as a polyethylene film cut on the surface of the surface material 6 into strips having a width of 5 to 30 cm. The reinforcing member 26 is formed by stacking.

The molded ceiling base material having such a structure is manufactured by the following steps. First, a thermoplastic resin film is overlaid on the front and back surfaces and heated and pressed while the reinforcing member 25 is overlaid on the peripheral edge portion 15 of the fiber forming the board material 11, that is, the non-woven fabric of glass fiber and thermoplastic fiber. As a result, the surface materials 6 and 7 are obtained on the front and back surfaces of the board material 11. At the same time, the reinforcing member 25 is integrated with the hoard member 11, and the reinforcing member 25 and the edge portion 15 of the board member 11 are compressed to the same thickness as the central portion 5. Further, the reinforcing member 26 is overlapped on the front and rear surfaces of the obtained board material 11 and hot pressed or laminated at a temperature equal to or higher than the melting point thereof, whereby the reinforcing member 26 is fused on the surface material 6 and at the same time, the reinforcing member is formed. The surface 26 is flush with the surface material 6. In this way, the flat plate-shaped board material 11 whose periphery is reinforced by the reinforcing members 25 and 26 is press-molded into a predetermined shape by a molding press machine, whereby a molded ceiling base material having the same external shape as that shown in FIG. Is formed.

In the molded ceiling base material of this embodiment having the above-described structure, the left and right reinforcing portions 3 and 4 have the fibrous reinforcing member 25.
With the structure in which the rigidity is increased by stacking and increasing the basis weight, the basis weight of the peripheral portion of the board material 11 can be easily increased by a simple process. In addition, the front and rear reinforcing portions 1 and 2 are configured to be bonded with the thermoplastic resin film reinforcing member 26 to increase the rigidity, so that the front and rear sides can be easily increased in rigidity by a simple process while suppressing an increase in weight. Can be increased to In particular, by using a material having a high tensile strength such as a polyethylene film, the bending strength becomes large, and the extremely thin and lightweight reinforcing member 26 can also have a large rigidity.

The weight per unit area of the reinforcing member 25 may be smaller than the weight per unit area of the board material 11, or may be the same or larger than that. In any case, the reinforcing member 25 is used as the board material 11
Due to the stacking, the total basis weight of the peripheral portion 15 of the board material and the reinforcing member 25 is larger than the basis weight of the board material 11. The reinforcing member 25 is not only a non-woven fabric obtained by mixing and spinning glass fibers and thermoplastic resin fibers of the same quality as the board material 11, but also a woven fabric of the same material, a woven fabric or non-woven fabric of organic fibers, or a thermoplastic resin film. Is also good. In addition to the method of stacking a strip-shaped member which is separate from the board material 11, the reinforcing member 25 has 5 to 30 cm at the left and right ends of the board material 11.
It can also be formed by a method in which the extension is formed to some extent, and the extension is folded back and polymerized.

The front and rear left and right reinforcing members 25 and 26 are
One or both of them may be provided on both front and back surfaces of the board material 11. (Third Embodiment) Next, FIG. 7 shows an external configuration of a molded ceiling base material 30 according to a third embodiment of the present invention, and FIG. 8 shows an external configuration thereof before press molding. Note that, in FIG. 8, the dimension in the height direction is enlarged and exaggerated for ease of explanation. The base material 30 of this embodiment is obtained by polymerizing a frame-shaped reinforcing member 32 surrounding the periphery of a fibrous board material 31 cut into a rectangular shape as shown in FIG. After polymerizing 33, heat press molding with a press molding machine,
It is manufactured by further trimming. Reinforcing parts 41 to 44 are formed on the periphery of the base material 30 so as to surround the central part 45. Similar to the first embodiment, the front and rear reinforcing portions 41 and 42 are fixed to the front and rear sides of the inner circumference of the vehicle body by trims, or contacted when there is no trim.
Reference numerals 3 and 44 denote portions fixed to the left and right sides of the inner circumference of the vehicle body by side garnish. Further, in FIG. 7, the front surface side is a surface facing the vehicle interior, and the back surface side is a surface facing the vehicle body roof panel.

Similar to the first embodiment, the board material 31 is a non-woven fabric formed by mixing and spinning glass fibers and thermoplastic resin fibers into a flat plate shape, and has a total basis weight less than that of a conventional ceiling base material. It was done. On the front and back of the board material 31,
Surface layer 3 in which thermoplastic resin films are superposed and heat-fused or embedded (in a state of being melted and completely permeated)
4, 35 are formed.

The reinforcing member 32 is a thermoplastic resin film such as a polyolefin film, or a non-woven fabric made of thermoplastic resin fibers, and is heated at a temperature equal to or higher than the melting point of the thermoplastic resin film so that the surface layer 34 of the surface side of the board member 31 is formed. It is buried by being fused to the surface or by being melted into the board material 31 and completely permeated. This reinforcing member 3
The width of 2 is about 5 to 30 cm.

On the back surface of the board material 31, a multi-layer film 33 having an airtight and high melting point resin film 37 sandwiched between two hot melt films 36 and 38 is attached. The hot-melt films 36 and 38 have a melting point lower than the heating temperature of the press for molding the molded ceiling base material 30 of this embodiment into a predetermined shape, and are, for example, low-melting resin films such as polyolefin films. .. The high melting point resin film 37 is, for example, a PET film, and has a melting point higher than the heating temperature of the pressing machine. Therefore, the high melting point resin film 37 does not melt at the time of heat molding by a press machine and maintains airtightness.

The press-molded base material 30 has reinforcing portions 41 to 44 formed by frame-shaped reinforcing members 32 arranged at the front, rear, left and right peripheral portions thereof. The reinforcing portions 41 to 44
As a result, the bending strength of the peripheral portion is increased, which increases the rigidity of the base material 30 as a whole. Also, the reinforcing portion 4
Since 1 to 44 have the rigidity as a whole, the basis weight of the central portion 39 of the board material 31 can be reduced, so that it is possible to reduce the total weight of the base material 30 and reduce the weight of the interior material. Can be planned.

On the other hand, board material 31 made of fibrous material
Has air permeability because it has continuous voids between the fibers. For this reason, when a breathable skin material is used, dirty air in the passenger compartment flows through the ceiling base material, and the ceiling base material acts like an air filter. Dirt may adhere to the material. In contrast,
In the molded ceiling base material 30 of the present embodiment, the multilayer film 33 having the high melting point film 37 is attached to the back surface of the board material 31, so that the air in the vehicle interior allows the ceiling base material 30 to be exposed due to the airtightness of the high melting point film 37. It is possible to prevent the skin material from being soiled without passing through.

[0022]

As described in detail above, in the molded ceiling base material according to the present invention, reinforcing members are provided at the front, rear, left, and right peripheral portions to increase the rigidity of the peripheral portions, so that the entire base material is The rigidity can be increased. Therefore, the molded ceiling base material of the present invention does not bend when it is mounted on the vehicle body ceiling, and the peripheral edge portion does not hang down after mounting, and does not impair the appearance of the ceiling interior.

In addition, since the molded ceiling base material of the present invention can reduce the basis weight of the central portion of the board material constituting the molded ceiling base material by reinforcing the peripheral portion in the shape of a frame, the entire base material can be reduced. The weight can be reduced, and the weight of the interior material can be reduced.

[Brief description of drawings]

FIG. 1 is an external perspective view of a molded ceiling base material according to a first embodiment of the present invention.

FIG. 2 is a plan view showing a state before molding of a board material constituting the same base material.

3 is a cross-sectional view taken along the line AA in FIG.

FIG. 4 is a sectional view taken along line BB in FIG.

FIG. 5 is a view of a molded ceiling base material according to a second embodiment of the present invention.
It is an AA sectional view taken on the line.

FIG. 6 is a sectional view of the same substrate taken along the line BB in FIG. 1.

FIG. 7 is an external perspective view of a molded ceiling base material according to the third embodiment of the present invention.

FIG. 8 is an external perspective view showing the state of the same base material before press molding.

[Explanation of symbols]

1-4, 41-44 ... Reinforcing part 6, 7 ... Surface material 10,
30 ... Molded ceiling base material 11, 31 ... Board material 21-26, 32 ... Reinforcing member 33 ... Multilayer film

Claims (1)

[Claims] 1. A molded ceiling base material, which is formed by molding a fibrous board material having all peripheral portions reinforced into a predetermined shape.