JPS60197446A - Car ceiling structure - Google Patents

Abstract

PURPOSE:To improve the thermal insulation performance and the rigidity of roof panel by providing a foaming material layer composed of glassy or other inorganic material containing many independent foams at the cabin side of roof panel. CONSTITUTION:When applying on a suspension ceiling structure for car, an inorganic foaming material layer 10 is formed at the cabin side of roof panel 1. A head lining 2 is supported through predetermined space 20 at the inside of said foaming material layer 10 by means of some suitable supporting means to constitute a suspension ceiling. Glass foaming material, foamed concrete such as ALC concrete, inorganic foaming material such as water glass foaming material or layer material consisting of such particles as glass balloon, ''shiras balloon'', perlite, etc. is employed as the in organic foaming material layer 10 and preferably glass foaming material having the bulk specific gravity of 0.1-0.7 and the porosity of 65-98% is employed.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a ceiling structure in an automobile.
This invention relates to a ceiling structure for automobiles that has excellent sound insulation properties.

Generally, automotive ceiling structures are required to have functions and characteristics such as excellent heat insulation and light weight, and in order to satisfy these requirements, various automotive ceiling structures are required. body has been proposed.

However, especially when it comes to insulation.

As yet, a structure with excellent properties that satisfies these demands has not been provided, and the development of an automobile ceiling structure with excellent heat insulation is needed in order to avoid as much as possible the loss of horsepower due to cooling and heating inside the vehicle. was.

In other words, if we take the example of a decrease in horsepower due to air conditioning inside the car, the main reason for the rise in the car interior temperature in Auto East is the radiant heat from direct sunlight on the car body.
Current automobiles do not have sufficient measures to eliminate or prevent the transmission of heat into the cabin, and only large-scale measures are taken to prevent the temperature rise within a single cabin due to the sun's radiant heat. The reality is that it depends on the capacity of air conditioning equipment. However, the use of large-capacity air conditioning equipment in automobiles requires the consumption of a large amount of energy, and the engine output decreases by the amount of energy consumed by this air conditioning equipment, resulting in a decrease in the driving performance of the automobile due to the lack of engine horsepower. This is a drawback. Therefore, it has been desired to develop a ceiling structure for automobiles that has excellent heat insulation performance.

Therefore, in view of the above-mentioned problems with conventional automobile ceiling structures, the inventors of the present invention have conducted various studies to solve the problems, and as a result, they have come up with the present invention.

An object of the present invention is to provide an automotive ceiling structure with excellent heat insulation properties.

That is, the ceiling structure for an automobile according to the present invention is characterized by comprising a roof panel of an automobile and an inorganic foam layer made of an inorganic material containing closed cells and provided on the indoor side of the roof panel.

The automobile ceiling structure of the present invention has an inorganic foam layer with excellent heat insulation properties arranged on the ceiling inside the tail of the automobile, so this heat insulation foam layer containing a large number of closed cells can absorb heat inside and outside the vehicle interior. It can provide insulation and reduce the cooling and heating effects within a single room.

Therefore, heating and cooling equipment such as air conditioners can be made small, small in capacity, and inexpensive.

In addition, the engine load caused by the use of heating and cooling equipment such as air conditioners is reduced, thereby improving the driving performance of the vehicle, resulting in energy saving effects and making a significant contribution to maintaining the health of drivers.

Further, the heat insulating foam layer used in the ceiling structure of the present invention has sound insulation and sound absorption effects, and can make the interior of a single room quiet.

Furthermore, the inorganic foam layer of the ceiling structure of the present invention is lightweight, has a very low water absorption rate, is nonflammable, and can be used in a wide range of temperatures from low to high temperatures.

It can be used in any weather. Particularly in the case of vitreous foam, its operating temperature ranges from extremely low/M (-20o'c) to high temperature (4oC).

``C), so its range of use is extremely wide. Therefore, this ceiling structure also has excellent fire resistance.

The automobile ceiling structure of the present invention has the following aspects (Js)
obtain.

The first aspect of the present invention is of a type used for suspended ceilings, as shown in FIG. 1, a cross-sectional view of which is illustrated.

The present invention is characterized by comprising a roof panel 1 for the ceiling of an automobile, a solid foam PIIjJ1o formed on the indoor side of the roof panel, and a headlining 2. In the figure, 20 indicates space. (The same applies to the following figures) According to the present application, in addition to the above effects, the rigidity of the inorganic foam layer disposed on the indoor side of the roof panel can be increased. Also.

This inorganic foam layer does not shrink or otherwise deform even if the roof panel becomes hot due to solar heat or the like.

The second aspect of the present invention is of a type used for suspended ceilings or molded ceilings, and as illustrated in FIG. 2, it consists of a roof spring/L/1 and a ceiling interior material 30.

The ceiling interior material is characterized by comprising an inorganic foam layer 10 and a skin material 5 formed on the blank side surface of the inorganic foam layer.

In addition to the effects of the present invention described above, the second aspect also has the following effects. In other words, the ceiling interior material has a very simple structure consisting of an inorganic foam layer and a skin material formed on the surface of the inorganic foam layer, so it is very easy to manufacture.
It can be done cheaply.

The fifth aspect of the present invention is of a type used for suspended ceilings or molded ceilings, and comprises a roof spring A/1 and a ceiling interior material 30, as illustrated in FIG.

The ceiling interior material is characterized by comprising an inorganic foam layer 10, a cushion material 4 coated thereon, and a skin material 5 further coated thereon.

According to the sixth aspect, in addition to the above-mentioned effects, since the cushioning material is disposed between the inorganic foam layer and the skin material, the durability is even better than that of the second aspect.

It also has the effect of protecting the inorganic foam layer.

-6- Furthermore, since this cushioning material has heat insulating properties and sound absorbing/sound insulating properties, it is possible to provide a ceiling structure for an automobile with further excellent heat insulating properties, sound absorbing/sound insulating properties.

The fourth aspect of the present invention is of a type used for suspended ceilings or molded ceilings, and as illustrated in FIG. 4, it consists of a roof panel 1 and a ceiling interior material 6o.

The ceiling interior material is characterized by comprising a base material 6, an inorganic foam layer 1o coated on the base material, and a skin material 5 coated thereon.

According to this aspect, in addition to achieving the effects of the present invention,
Compared to the second aspect, the rigidity can be increased.

The fifth aspect of the present invention is of a type used for suspended ceilings or molded ceilings, and as illustrated in FIGS. 5 and 6, it consists of a roof panel 1 and a ceiling interior material 6°, the ceiling interior material comprising: It is characterized by comprising a base material 6, an inorganic foam layer 1o coated on either side of the base material 3, a cushion material 4, and a skin material 5 coated thereon.

According to this aspect, the effects of the fifth aspect and the fourth aspect described above can be combined more effectively.

The sixth aspect of the present invention is of a type used for beam ceilings, and as illustrated in FIG. It is characterized in that it consists of a covered skin material 5.

In addition to the effects of the present invention described above, the sixth aspect also has the following effects. That is, the inorganic foam layer formed on the indoor side of the roof panel can increase the rigidity of the roof panel.

Moreover, this inorganic foam layer does not undergo deformation such as shrinkage even if the roof panel becomes hot due to solar heat or the like. Furthermore, since it is possible to create a structure in which a laminate consisting of an inorganic foam and a skin material is adhered to the entire surface of the indoor side of the roof panel, it can be formed very easily and the manufacturing cost is low. .

In addition, indoor space can be used effectively.

The seventh aspect of the present invention is of a type used for beam ceilings, and as illustrated in FIG. 8, includes a roof panel 7-1 and an inorganic foam layer 1o formed on the indoor side thereof.

It is characterized by comprising a cushion material 4 coated on the surface thereof, and a skin material 5 further coated thereon.

According to this aspect, in addition to the above-mentioned effects, since the Kutsushiran material is disposed between the inorganic foam layer and the skin material,
It has better covering properties than the embodiment, and also has the effect of protecting the inorganic foam layer.

The eighth aspect of the present invention is of a type used for beam ceilings, and as illustrated in FIG. It is characterized in that it consists of the formed inorganic foam layer 1o, a cushion material 4, and a skin material 5.

The second aspect can be combined more effectively than the sixth and seventh aspects.

-81 The ninth aspect of the present invention is of a type used for beam ceilings, and as illustrated in FIG.
It is characterized by comprising an inorganic foam layer 10 disposed on the indoor side, and a base material 6, cushion materials 4, and 9 and a skin material 5 laminated in sequence on the surface of the inorganic foam layer 10.

The ninth aspect can more effectively combine the effects of the sixth aspect and the seventh aspect.

Here, the inorganic foam layer used in the present invention includes glass foam, AL (3) aerated concrete such as concrete, and inorganic foam such as water glass foam.

and glass balloons, Gawo Speed, Shirasu balloons,
A layered material of particles such as pearlite is used.

Further, in the above, the glass foam has excellent effects particularly in terms of heat insulation properties and mechanical strength, since the cells inside the glass foam are independent from each other and do not communicate with each other. Among them, bulk specific gravity is 0.1 to 0.7. Porosity is 65-9
In the case of 8%, a particularly excellent heat insulating effect is achieved.

Furthermore, the bulk specific gravity is 0.15 to 0.3. Porosity is 85-97
%, it has an even better heat insulating effect.

Such a glass foam can be manufactured as follows.

That is, this glass foam was manufactured using glass powder and a foaming agent. 9 as a raw material for glass powder
Various glass powders such as ordinary soda lime glass, borosilicate glass, lead glass, soda silicate glass, etc. are used. Further, as the blowing agent, a substance is used which can thermally decompose or oxidize at the softening temperature of the glass powder to generate gas and generate a large number of bubbles in the softened inorganic material. Typical examples include calcium carbonate, dolomite, silicon carbide, carbonate mag*, which are substances that decompose at the softening temperature of glass powder to generate carbon dioxide, oxygen, etc. ! /+74
In the latter case, examples include carbon powder, which is a substance that burns at the softening temperature of glass powder and generates carbon dioxide gas, etc.

In producing this glass foam, a foaming mold of a desired shape is prepared, and the above-mentioned raw materials are placed in the mold and heated. The obtained glass foam may be used as it is, or may be processed into a desired shape.

Further, the glass foam can be made into a glass foam having a desired shape by forming vitreous hollow multi-cell particles in advance and molding the vitreous hollow multi-cell particles using a binder or the like. Furthermore, the vitreous hollow foam particles may be simply stuffed into a sealed space formed between the roof panel and the ceiling interior material (for example, the base material) (see FIG. 14). Alternatively, the pressure within this sealed space may be lowered to achieve close contact.

Hollow multi-cell beads can be produced using a normal glass bead manufacturing method.A simple manufacturing method is as follows: 9. A raw material mixture is prepared by coating a pore-forming material such as expanded polystyrene, and then the raw material mixture is placed in a heating furnace and subjected to primary heating at a temperature lower than the softening temperature of the glassy powder.

The pore-forming substance forms pores. Next.

Further, secondary heating is performed at a temperature higher than the softening temperature of the vitreous powder to foam the vitreous powder, thereby making it possible to obtain vitreous hollow multicellular particles. Here, the vitreous powder and foaming agent are
Those similar to those described above can be used. Also,
The pore-forming substance used is a substance that disappears or decreases in volume through thermal decomposition or oxidation at a temperature relatively lower than the softening temperature of the glassy powder, and forms pores in the raw material mixture. Typical examples thereof include organic materials such as 9-foamed Boristyre waste, and inorganic materials such as carbon powder and water glass foam.

These vitreous hollow foam particles consist of a vitreous body constituting a main body, and a central hole formed inside the vitreous body at approximately the center. Moreover, the glassy material contains a large number of closed cells therein.

These vitreous hollow multi-cell particles are designed by taking heat insulation properties into consideration.
An appropriate shape, two particle sizes, one volume weight, pore shape, and pore diameter can be selected. Particle size is 0.1 to 10
The FF type has a particularly low bulk density, is lightweight, and has excellent heat insulation properties. Further, the diameter of the pores is preferably in the range of 0.5 to 0.85 with respect to the particle size.

The roof panel is a structural material that forms the roof of an automobile, and is made of a metal panel such as a 1W4 iron plate, a plastic panel, or the like.

Furthermore, the headlining is made of molded cardboard.

Polyvinyl chloride film, nonwoven fabric,
A material coated with a skin material such as woven cloth, vinyl sheet, cloth, etc. is used. Incidentally, the second skin material may be covered with a lace material such as urethane foam or foamed polyethylene foam.

The base materials are materials that provide rigidity to ceiling interior materials, such as molded cardboard, molded hardboard, plywood, molded pulp, molded felt, glass fiber, cardboard plastic, and vinyl chloride sheets.

Use rigid materials such as polyethylene sheets, lath nets, expanded metal, molded paper 2 reinforced plastics, etc.

The cushioning material imparts cushioning properties from the indoor side, and uses soft organic foams such as urethane foam, polyethylene foam, polyolefin sheets, and polystyrene foam, woven fabrics, nonwoven fabrics, and the like.

Further, as the skin material 9, single-layer resin leather such as vinyl chloride resin, urethane resin, acrylic resin, fabric, woven fabric, non-woven fabric, cloth such as cloth, vinyl sheet, etc. are used.

Various conventional methods can be applied to construct this automotive ceiling structure, and typical methods are shown below.

/r −4=龜 − First, a typical manufacturing method will be described for an automobile ceiling structure of a type used for a molded ceiling or the like.

In the case of this molded ceiling type, the ceiling structure consists of a roof panel 1 and a ceiling interior material 5°, as shown in FIG. It is constructed by inserting it into the tool 40 or the like. The ceiling interior material includes the inorganic foam 10 and the skin material 5 manufactured by the above-mentioned manufacturing method, and the cushion material 4 as appropriate depending on the purpose, properties, etc. It is constructed by laminating the base material 3 and the like.

For this lamination, methods include bonding with adhesive, fusion by heating, fixing by using fasteners, etc.

Use conventional lamination methods. Moreover, it can be manufactured by a method in which each member is laminated simultaneously when manufacturing each member in advance.

Next, a typical manufacturing method for an automobile ceiling structure of the type used for a ceiling panel or the like will be described.

In the case of this ceiling type, the ceiling structure includes, as shown in FIG. 12, a roof panel 1, an inorganic foam 10 on the indoor side, and a skin material 5. And the purpose/6 one! ---Customer material 4. as appropriate depending on properties etc. It is constructed by laminating the base material 3 and the like. In this case, for the lamination,
It is obtained by laminating previously manufactured members using a common lamination method. In addition, the materials to be laminated to the roof panel are laminated in advance, and the surface to be adhered to the roof panel has weather resistance and
A pressure-sensitive adhesive with excellent heat resistance is laminated, a release material is temporarily attached on top of it, and when this laminate is bonded to a roof panel, the release material is peeled off and the adhesive layer is used. It can be attached to the indoor side of the roof panel.

Furthermore, when using the inorganic foam layer directly on the indoor side of the roof panel when used for a pasted ceiling, etc., a sealed space is formed between the roof panel and the ceiling interior material (for example, the base material). This space may be filled with inorganic hollow foam particles, and the internal pressure of the sealed space may be lowered to fix the inorganic hollow foam particles in the sealed space to form an inorganic foam layer. At this time, when the inorganic hollow foam particles and the adhesive are mixed and sealed in the sealed space to form the inorganic foam layer, the inorganic foam layer is bonded by the adhesive. , the inorganic foam layer can be kept in a constant shape.

Embodiment 1 This embodiment belongs to the first aspect of the present invention, and is of a type used for a suspended ceiling, as shown in FIG. The inorganic foam layer 10 attached to the ceiling and a headlight tension steel plate were press-molded into a predetermined shape.

Next, 100 parts by weight of soda glass powder as an inorganic powder as a raw material for an inorganic foam and 5 parts by weight of dolomite as a blowing agent were added, and the resulting mixed powder was finely pulverized and mixed. heating and heating in the desired mold.
A glass foam having a predetermined shape was obtained by foaming. The bulk specific gravity of this glass foam was [125], and the porosity was 95%.

Next, on one surface of this glass foam 10, pressure-sensitive adhesive layers 1 and 1 of fibers having excellent weather resistance and heat resistance are laminated, and a paper release layer is further layered on the outside thereof. I temporarily attached the mold material.

Additionally, a PVO leather seat was prepared as Head Fining 2.

The structure of the automobile ceiling structure of this example is such that the release material temporarily attached to the adhesive layer provided on the surface of the glass foam is separated by -1t'lI, and the adhesive layer is used to attach it to the indoor side of the roof panel. Dressing 2 Next, the PVC leather sheet is lifted and fixed using a listing wire.

The automobile ceiling structure having the above structure has a glass foam layer provided on the indoor side of the /L/- panel.

It has excellent insulation properties and also has excellent noise and sound absorption properties.

Moreover, the rigidity of the W-panel can be increased by the glass foam layer disposed on the indoor side of the roof panel. Furthermore, the glass foam layer does not shrink or deform even if the roof panel becomes hot due to solar heat or the like.

Embodiment 2 This embodiment belongs to the fifth aspect of the present invention and is of the type used for a molded ceiling, as shown in FIGS. 5 and 11. A ceiling interior material 60 consisting of an interior material 30, a base material 6, an inorganic foam layer 10 coated on the surface thereof, a cushion material 4 coated on the surface thereof, and a skin material 5 coated thereon. ) The V-panel 1 is configured by being inserted into a fitting 40 provided in an appropriate opening at the indoor end.

First, 31al obtained by the same method as in Example 1 was applied to one surface of a 0.8+u thick hardboard as a base material.
Thick glass foam (high specific gravity 0.20, porosity 97%)
Firstly, polyurethane foam of two thicknesses was laminated as a lace material, and then vinyl chloride leather was covered as a skin material to obtain a ceiling interior material.

Next, this ceiling interior material 60 is coated with /L/-panel 1
Insert it into the fitting tool 40 provided at the indoor end of the.

A ceiling structure for automobiles was constructed.

The automatic military ceiling structure with the above structure has a structure with very good heat insulation because the ceiling interior material having a glass foam layer with excellent heat insulation properties is fitted onto the indoor side of the roof panel. It is the body.

Moreover, since the ceiling interior material has a glass foam layer containing a large number of closed cells, the ceiling structure has excellent sound insulation and sound absorption properties.

Furthermore, since it has a structure in which hardboard and polyurethane foam are laminated on the surface of the glass foam layer, it is possible to further improve cushioning properties from the inside of the passenger compartment and protect the glass foam layer.

Further, in this ceiling structure, since the ceiling interior material has high rigidity, sagging and the like do not occur.

Embodiment 6 This embodiment belongs to the sixth aspect of the present invention, and is of a type used for a ceiling, as shown in FIG. It consists of an inorganic foam layer 10 and a nose material 5 coated on the surface of the inorganic foam layer.

First, a glass foam (high specific gravity) obtained by the same method as in Example 1 and having a thickness of 7' α23. Porosity 97%) is weather resistant.

Adhesion using a rubber adhesive with excellent heat resistance (71 then 2
Aku IJ as the skin material 5) was coated with resin leather to form a ceiling structure for an automobile.

The automobile ceiling structure with the above structure is made by providing a glass foam with excellent heat insulation on the indoor side of the roof panel.
It has excellent heat insulation properties and excellent sound absorption performance. Additionally, the glass foam layer formed on the indoor side of the roof panel can reduce the rigidity of the roof panel.

Furthermore, the glass foam layer does not shrink or deform even if the roof panel becomes hot due to solar heat or the like, and can be used in a wide temperature range from extremely low temperatures to high temperatures.

In addition, since it has a very simple configuration, there are fewer two work steps,
Manufacturing costs are low, and indoor space can be used effectively.

Embodiment 4 This embodiment belongs to the ninth aspect of the present invention, and is of a type used for a ceiling panel, and as shown in FIG. 10 and FIG. Inorganic foam layer 10 using vitreous hollow multicellular particles
and the base material 3 laminated on the surface thereof.

It is composed of a cushioning material 4 laminated on the surface thereof, and a skin material 5 covering the surface thereof.

First, a high tensile strength steel plate having a thickness of 0.7 mm was press-formed into a predetermined shape as the /L/- panel 1.

Next, as a base material, a reinforced plastic made of phenolic resin and glass fiber was molded to a thickness of 1 nm using a press molding method.
It was molded into a predetermined shape.

Furthermore, as shown in FIG.
fffi, vitreous hollow foam particles 15 with a specific gravity of 0.3 and a suitable adhesive 16 are placed in a scorchable bag 50 made of synthetic resin, and these are attached to the roof panel 1 and the base material 6. The roof panel 1 and the base material 6 were inserted and bonded together, and the peripheral edges of the roof panel 1 and the base material 6 were bonded except for the conduit 51 provided at one end of the nine-bag body 50.

3. No. L -- Next, the suction device 60 was connected to the conduit 51 of the bag 50. This suction device consists of an air filter 61 that prevents dirt from flowing in from the bag, and a regulating valve 62 that adjusts the internal pressure of the bag.
An internal pressure measuring device 66 that measures the internal pressure of the bag, and a valve 64 that shuts off the conduit.

It consists of a vacuum pump 65 that lowers the internal pressure of the bag.

Then, the vacuum pump 65 is driven to lower the internal pressure of the bag body 50, and the layer of vitreous hollow multi-cell particles in the bag body 5 settles into a predetermined shape between the roof spring/L/1 and the base material 3. Let it happen. Thereafter, the suction device 60 is removed from the conduit 51, and a cap (not shown) is fitted onto the conduit 51. In the foam layer formed in this way, which is formed of the glassy hollow multicellular particles, the hollow multicellular particles are fixed to each other by the adhesive, and the shape as a whole is maintained constant.

Next, on the surface of the base material 6, 5, 511
A ceiling structure for an automobile was prepared by laminating polyurethane foam having a thickness of 8 mm and covering it with PVC leather as a skin material 5.

The automatic military ceiling structure with this configuration has excellent heat resistance! - Since it is formed of an inorganic foam layer consisting of a glassy hollow multi-cell layer and a polyurethane foam layer, it has excellent heat insulation properties.

In addition, it is an excellent cushioning material for the indoor side, and has a good feel to the touch and a beautiful surface.

Furthermore, the rigidity of the roof panel can be increased by the inorganic foam layer and base material disposed on the indoor side of the roof panel.

Furthermore, the inorganic foam layer formed on the indoor side of the roof panel has a very wide operating temperature range of 1,200°C to 400°C, and does not deform due to changes in the external environment.

Therefore, it is also possible to apply baking paint to the vehicle body after assembly.

[Brief explanation of drawings]

1 to 10 are cross-sectional views schematically illustrating representative examples and embodiments of the automobile ceiling structure of the present invention;
Figure 1 is a side cross-sectional view of a molded ceiling type automatic military ceiling structure, Figure 12 is a side cross-sectional view of a pasted ceiling type automobile ceiling structure, and Figures 15 and 14 of the second furnace are In the figure showing an example. FIG. 13 is an explanatory diagram showing a suction device attached to a ceiling structure, and FIG. 14 is a side sectional view of the ceiling structure. 1... Roof panel 2... Headlining 3
...Base material 4-Soda/Cushion material 5...Skin material 1
0... Inorganic foam layer 20... Space 30... Ceiling interior material 40... Fitting tool patent applicant Toyota Central Research Institute 1 - Takel --- Mouth () Regret

Claims (1)

[Claims] (11) A ceiling structure for an automobile characterized by comprising a roof panel of a TLJ vehicle and an inorganic foam layer made of an inorganic material containing a large number of closed cells provided on the interior side of the roof panel. (2) The automobile ceiling structure according to claim (1), wherein the inorganic foam layer is a glass foam layer made of vitreous material containing a large number of closed cells. 3) The inorganic foam layer is composed of glass, a solid body made of glassy hollow multicellular particles, and pores formed approximately in the central portion, and the glassy body is An automatic military ceiling structure according to claim 1, characterized in that the structure contains a large number of closed cells inside.