JPH08258634A - Molded ceiling material for vehicle - Google Patents

Abstract

PURPOSE: To provide a molded ceiling material having impact relieving function which does not require provision of any pad separate from the ceiling material by setting the thickness to any desired value through utilization of a stratified molding of ceiling material. CONSTITUTION: A molded ceiling material 1 for vehicle has at least a urethane foam layer, whose thickness is made smaller in the oversurface part 2 of the ceiling material and made greater in the side face parts and/or front and rear surfaces 4 so that the impact at vehicle collision can be absorbed.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a molded ceiling material for a vehicle, and more particularly, to a side wall portion and / or a front and rear surface portion of a molded ceiling material using a layered molded article to provide an impact at the time of a vehicle collision. The present invention relates to a molded ceiling material having a relaxation function.

[0002]

2. Description of the Related Art Conventionally, as a molded ceiling material for vehicles, a glass reinforced type using a thermoplastic thermoform has been known. As shown in FIG. 8 (B), the glass-reinforced type molded ceiling material 100 has a sandwich-like layered structure of a skin 102, a glass chop 104, a thermoform 106, a glass chop 104, and a skin 102 in this order. The hot-melt film 108 was inserted between these layered components, heated, and then press-molded to form a molded ceiling material. By the way, in recent years, safety measures for vehicles have become of great concern, but conventional molded ceiling materials may not always be sufficient as countermeasures against collisions on the side or front of the vehicle. This is because there is a limit to increase the wall thickness of the thermoform layer, so that it is difficult to secure the shock absorbing function at the side surface portion and the front and rear surface portions of the molded ceiling material. Therefore, in the case of the conventional molded ceiling material, as shown in FIG.
As shown in (A), a pad 110, which is separate from the molded ceiling material, is attached to the side surface portion and the front and rear surface portions of the molded ceiling material, so that the head of the occupant is positioned on the side surface of the molded ceiling material when the vehicle side collision occurs. When it hits the front part or front and back parts, the impact is applied to the pad 11
It was absorbed and alleviated by 0 to protect passengers.

[0003]

However, according to such a structure, the side surface portion and the front and rear surface portions of the molded ceiling material are separated from the molded ceiling material in order to reduce the impact of the side surface portion and the front and rear surface portion of the ceiling at the time of collision. Since the pad is attached, there is a problem that the number of parts is increased, the work efficiency is reduced, and the cost is increased. Therefore, the present invention has a shock absorbing function by freely setting the wall thickness by using the layered molded product of the molded ceiling material, and does not require attachment of a pad separate from the molded ceiling material. An object is to provide a molded ceiling material.

[0004]

In order to solve the above-mentioned problems, the present invention has the following means. That is,
A first aspect of the present invention is a molded ceiling material formed of at least a urethane foam layer and having a predetermined shape to be a vehicle ceiling, wherein the urethane foam layer is thin in a portion serving as an upper surface portion of the ceiling. The gist of the present invention is that it is formed in the shape of a wall, and the side surface portion and / or the front and rear surface portions of the ceiling are formed thick. The invention according to claim 2 is the molded ceiling material for a vehicle according to claim 1,
The gist is that the urethane foam layer is made of urethane foam. A third aspect of the invention is the molded ceiling material for a vehicle according to the second aspect, in which glass fibers are mixed in the urethane foam forming the urethane foam layer.

[0005]

According to the invention of claim 1, the thin portion of the urethane foam layer is disposed on the upper surface portion of the vehicle ceiling, and the thick portion of the urethane foam layer is formed on the side surface portion of the vehicle ceiling and / or
Alternatively, the urethane foam layer on the thin wall does not interfere with the necessary space in the vehicle compartment because it is placed on the front and rear surfaces, and the urethane foam layer on the thick wall has a function of cushioning the impact in the event of a vehicle collision. Have. Further, according to the second aspect of the invention, since the urethane foam layer is formed of urethane foam, an excellent impact relaxation function is obtained and the moldability is also improved. Further, according to the invention of claim 3, since glass fibers are mixed in the urethane foam forming the urethane foam layer, in addition to the shock absorbing function, the strength characteristics of the molded ceiling material can be improved. .

[0006]

Embodiments of the present invention will be described below with reference to FIGS. The molded ceiling material 1 of this embodiment is shown in FIG.
(C), the urethane foam layer 10, the slab urethane layer 12 and the skin material 14 are integrally formed.

The urethane foam layer 10 is shown in FIG.
As shown in (C), the molded ceiling material 1 is formed by forming the outer surface side of the molded ceiling material 1 and appropriately adjusting the thickness thereof.
The side surface portion 4 serves as one layer of the layered molded product S of the molded ceiling material 1 that imparts the shock absorbing function. The urethane foam layer 10 is thin on the upper surface portion 2 of the molded ceiling material 1,
The thickness is increased as it moves from the upper surface portion 2 to the side surface portion 4, and the thickness is changed so that the maximum thickness portion 6 is formed on the side surface portion 4. In addition, as shown in FIG. 3 and FIG.
The same applies to the front and rear surface portions 4f and 4r.
This is because the upper surface portion 2 of the molded ceiling material 1 has a thin wall to secure a space in the room, and the side surface portion 4, the front surface portion 4f, and the rear surface portion 4r.
This is because the thick wall has a shock absorbing function. Specifically, the urethane foam on the upper surface portion 2 of the molded ceiling material 1 is
It is preferable that the wall layer 10 has a wall thickness of 1.5 mm to 10 mm, and the side walls and front and rear walls have a wall thickness of about 10 mm to 50 mm. Further, it is preferable to use urethane foam which is excellent in shock absorption for the urethane foam layer 10, and it is preferable to mix glass fiber into the urethane foam at the time of molding in order to improve strength characteristics. These correspond to the invention of claim 2 and the invention of claim 3, respectively. Further, by mixing, for example, felt / polystyrene into the urethane foam layer 10 at the time of molding, it is possible to improve the molding characteristics and the weight characteristics in addition to the impact relaxation function.

The slab urethane layer 12 is shown in FIG.
As shown in (C), it is a member that forms one layer of the layered molded product S of the molded ceiling material 1, and has a urethane foam layer 10 at the time of molding.
In order to prevent unevenness on the skin material 14 due to the foaming gas 27 generated in (see FIG. 7C), the skin material 14
It is formed by impregnating the porous core material 20 inserted between the urethane foam layer 10 and the urethane foam layer 10 with the urethane foam 26 (see FIGS. 7A and 7B). It should be noted that this formation is similarly performed on the front and rear surface portions of the molded ceiling material 1 shown in FIGS. 3 and 4.

The skin material 14 is a member of the molded ceiling material 1 that appears on the inside of the room, and is made of, for example, a material such as vinyl chloride, floki leather, or non-woven fabric. This is because it is preferable to use a material rich in decorativeness from the viewpoint of interior decoration. An adhesive film 16 is inserted between the skin material 14 and the slab urethane layer 12, as shown in FIGS. It should be noted that this formation is similarly performed on the front and rear surface portions of the molded ceiling material 1 shown in FIGS. 3 and 4.

The molded ceiling material 1 is integrally formed by integral foam molding. That is, as shown in FIG. 7A, the skin material 14 is set on the lower mold 30, and the skin material 14
A core material 20 with an adhesive film (not shown) interposed therebetween.
Set. Then, the urethane 2 is injected by the injection machine 24.
Inject 2. Here, the core material 20 is previously provided on the skin material 14.
Is set to prevent foaming gas when urethane is foamed. That is, the slab urethane layer 12 is formed by impregnating the core material 20 with the urethane foam 26 by the gas pressure of the foaming gas 27 generated when the urethane 22 is foamed (see FIG. 7B). If the core material 20 is not used, as shown in FIG. 7 (C), the foaming gas 27 directly acts on the skin material 14 to cause unevenness on the skin material 14, resulting in the molded ceiling material 1 after molding. The aesthetics of is spoiled.
Therefore, it is preferable to use the core material 20 at the time of molding.
Next, as shown in FIG. 7B, the upper mold 28 is set on the lower mold 30 and the mold is closed. Here, the molding portions of the upper mold 28 and the lower mold 30 are formed in conformity with the shape of the molded ceiling material 1. Further, glass fibers are mixed in advance with the injected urethane 22. Then, the urethane 22 is foamed to form the urethane foam 26, and the urethane foam layer 10 is formed. After the urethane foam 26 is cured, the mold is opened and the mold is released. Thus, the molded ceiling material 1 of the present embodiment is obtained by integrally forming the urethane foam layer 10, the slab urethane layer 12, and the skin material 14 into a layered molded product S.

The molding method of the molded ceiling material 1 is not limited to the above-mentioned method. For example, after the liquid raw material is discharged and mixed by a high-pressure injection machine, it is injected and injected into a mold and heated inside the mold. Reaction injection molding (RIM; Rea)
(action injection molding)
Or reinforced reaction injection molding (R-RIM; Re that improves strength characteristics by mixing reinforcing materials such as glass fiber into urethane.
Alternatively, it may be molded by an informed RIM).

The molded ceiling material 1 thus molded is incorporated into the roof 8 of the vehicle (see FIG. 5). That is, as for the side surface portion 4, as shown in FIG. 1, the side wall portion 4 of the molded ceiling material 1 formed in a thick wall shape is provided on a roof panel (not shown) of a vehicle. The molded ceiling material 1 is positioned by positioning the molded ceiling material 1 on the roof trim of the vehicle by engaging the mounting portion 36 formed at the end of the molded ceiling material 1 with the opening trim 34 of the roof panel. 8
Incorporate into. Further, as shown in FIG. 3, the front surface portion 4f is aligned with the front window upper frame, and is attached to the opening trim 34 installed on the weather strip provided at the upper end portion of the windshield. On the other hand, the mounting portion 36 formed at the end of the molded ceiling material 1 is engaged and mounted. As for the rear surface portion 4r, as shown in FIG. 4, the rear surface portion 4r is aligned with the rear window upper frame, and is mounted on a weather strip provided on the upper end portion of the rear window glass.
The mounting portion 36 formed at the end of the molded ceiling material 1 is engaged with and attached to the opening trim 34. This allows
The molded ceiling material 1 is installed on the roof 8 of the vehicle. In the roof 8, the thick wall portion 6 of the molded ceiling material 1 is formed on the side surface portion 4 and the front and rear surface portions 4f and 4r shown by hatching in FIG. 6, and the thick wall portion 6 is formed on the side surface of the vehicle at the time of collision. Since the impact is mitigated, safety in the event of a vehicle collision will be improved.

In this embodiment, the molded ceiling material 1 is used.
Although the thick portion 6 is formed on the side surface portion 4 and the front and rear surface portions 4f and 4r, the thick portion 6 may be formed only on the side surface portion 4, for example. Alternatively, the thick-walled portion 6 may be formed only on the front surface portion 4f and / or the rear surface portion 4r without being formed on the side surface portion 4.

[0014]

According to the present invention, since the wall thickness is freely set by using the layered molded article of the molded ceiling material, the molded ceiling material itself has a shock absorbing function at the time of a vehicle collision,
The passenger's head is effectively protected. Further, since it is not necessary to attach a pad separate from the molded ceiling material, the number of parts can be reduced and the cost can be reduced.

[Brief description of drawings]

FIG. 1 is a view showing a state of a side surface portion of a molded ceiling material of an embodiment assembled on a roof of a vehicle, and is shown in FIGS.
It is a III-III sectional view taken on the line.

FIG. 2A is a front sectional view of a molded ceiling material,
(B) is the upper surface of the molded ceiling material, that is, I in FIG. 2 (A)
-I line sectional view, (C) is a side surface portion of the molded ceiling material, that is, a II-II line sectional view of FIG. 2 (A).

FIG. 3 is a view showing a state of a front surface portion of a molded ceiling material of an embodiment mounted on a roof of a vehicle, which is shown in FIGS.
FIG. 4 is a sectional view taken along line IV-IV.

FIG. 4 is a view showing a state of a rear surface portion of a molded ceiling material of an embodiment assembled on a roof of a vehicle, and is a sectional view taken along line VV in FIGS. 5 and 6.

FIG. 5 is a perspective view of a vehicle in which the molded ceiling material of this embodiment is assembled.

FIG. 6 is a state view of the vehicle in which the molded ceiling material of the present embodiment is assembled, as viewed from the inside of the vehicle.

7A and 7B are views showing a forming process of the formed ceiling material of the present embodiment, FIG. 7A is a state diagram of urethane injection, FIG. 7B is a state diagram of mold closing, and FIG. It is sectional drawing of the molded ceiling material in case a core material is not inserted.

8A is a front sectional view of a conventional molded ceiling material, and FIG. 8B is a sectional view showing a state of the layered molded product.

[Explanation of symbols]

 1 Molded Ceiling Material 6 Thick Wall 10 Urethane Foam Layer 14 Skin Material 26 Foam Urethane 32 Opening Trim 36 Mounting Part

Continuation of the front page (51) Int.Cl. ⁶ Identification code Office reference number FI technical display location B29K 309: 08

Claims (3)

[Claims] 1. A molded ceiling material, which is made of at least a urethane foam layer and is molded into a predetermined shape to serve as a vehicle ceiling, wherein the urethane foam layer is thin in a portion serving as an upper surface portion of the ceiling. A molded ceiling material for a vehicle, wherein the molded ceiling material is formed to have a thick wall at a side surface portion and / or a front and rear surface portion of the ceiling. 2. The molded ceiling material according to claim 1, wherein the urethane foam layer is formed of urethane foam. 3. The molded ceiling material for a vehicle according to claim 2, wherein glass fibers are mixed in the urethane foam forming the urethane foam layer.