JPS63269749A - Automobile ceiling material and its manufacture - Google Patents

Abstract

PURPOSE:To improve surface strength of a ceiling material of a high sound absorbing property by laminating painted films on the surface of a foam body of a specified shape having a compact layer over its surface and laminating backing material over the other surface of this foam body. CONSTITUTION:A ceiling material 20 is formed into a specified shape by laminating a painted film 26 over the surface of a foam body 24 having a compact layer 22 over its surface and by laminating a backing material 28 over the other surface of the foam body 24. The compact layer 22 over the surface of the foam body 24 is formed by crushing surface pores to form a high density layer. For such a foam body 24, soft or semihard urethane foam which is likely to form the compact layer at the time of foam forming, namely integral skin urethane foam, is preferably used. A reinforcement material 30, if necessary, is embedded in the foam body 24. As the painted film 26, material consisting of urethane resin is preferably used while nonwoven cloth, woven cloth, paper, etc. are used for the backing material.

Description

DETAILED DESCRIPTION OF THE INVENTION (Industrial Field of Application) The present invention relates to a ceiling material for automobiles and a method for manufacturing the same.

(Prior art) The main conventional ceiling materials used as interior materials for automobiles are a core material made of a plate-like material of a predetermined thickness such as felt, paper, or plastic, and a surface material made of plastic leather or the like. The material and backing material are laminated and bonded. As shown in Fig. 3, the manufacturing method is to apply an adhesive to the laminated surfaces of the core material 10, the surface material 12, and the back material 14, press-form them using a press die 16, 18, and bond them together. This can be done by simultaneously shaping the material into the shape of the press mold surface, or by laminating and adhering the core material, surface material, and back material and then press molding in a separate process to shape the material into the shape of the press mold surface.

(Problems to be Solved by the Invention) However, there is a problem in that the automobile ceiling material cannot be said to have excellent sound absorption properties. In addition, since the thick core material is pressed into a predetermined shape, the front material or the back material is prone to wrinkles due to excessive elongation or deformation, and there is also the problem that the shape tends to return after manufacturing. .

This invention has been made to solve the above problems.

(Means for Solving the Problems) The automobile ceiling material according to the present invention has a coating film laminated on the surface of a foam having a dense layer on the surface, and a backing material laminated on the other surface of the foam. It is characterized by being

In addition, the manufacturing method for automobile ceiling materials involves forming a coating film on one cavity surface of a split mold, installing a backing material on the other cavity surface, and installing or not installing a reinforcing material in the remaining cavity. The method is characterized in that a raw material for forming a foam having a dense layer on the surface is injected, the foam is molded, and the foam, coating film, and backing material are integrated.

(Function) A foam having a dense layer on its surface has a higher surface strength than a normal foam due to the dense layer. Therefore,
The interaction between the dense layer and the coating film laminated thereon provides sufficient surface strength as a ceiling material for automobiles. Furthermore, the foam has a pore structure and has high sound absorbing properties due to its structure, so that this automotive ceiling material has high sound absorbing properties.

On the other hand, in this manufacturing method for automobile ceiling materials, the raw material for forming the foam having a dense layer on the surface, which is injected into the cavity, reacts and foams, surrounding the reinforcing material if it is installed in the cavity. It becomes a cavity-shaped foam. At the same time, due to the adhesive properties of the foam forming raw materials,
The foam is bonded and integrated with the coating film on the cavity surface and the backing material to form the above-mentioned automobile ceiling material.

Therefore, according to this manufacturing method, the foam is formed with the coating film and the backing material in close contact with or supported by the cavity surface, so that the coating film and the backing material do not stretch or deform.
Does not cause wrinkles.

Furthermore, since the foam is foam-molded into a cavity shape and fixed in shape, the foam does not naturally deform afterwards and can maintain its shape until it is attached to a vehicle.

(Example) The present invention will be explained below based on Examples.

FIG. 1 relates to one embodiment of the present invention, and is a partial sectional view of a ceiling material 20 for an automobile. Further, FIG. 2 is a sectional view of the split mold 40 at the time of manufacturing the ceiling material 20.

The ceiling material 20 has a predetermined shape in which a coating film 26 is laminated on the surface of a foam 24 having a dense layer 22 on the surface, and a backing material 28 is laminated on the other surface of the foam 24.

The foam 24 having the dense layer 22 on the surface has the pores on the surface crushed and the core portion becomes a dense layer to form the dense layer 22 . As the foam 24, a soft or semi-hard urethane foam in which a dense layer is formed during foam molding, that is, an integral skin urethane foam is suitable. Integral skin urethane foam has a density of 0.1~0.7g/crl and a thickness of 4~15+++
It is preferable to set it to m.

Further, a reinforcing material 30 is embedded in the foam 24 as required depending on the hardness of the foam. The reinforcing material 30 is selected and used in accordance with the shape of the ceiling material 20, such as a bar-shaped material such as metal or plastic, or a sheet-shaped material such as a glass mat.

The coating film 26 is preferably made of urethane resin, and among these, a non-yellowing or non-yellowing type is particularly preferable. This coating film 26 is the color of the interior of the car or the foam 2.
The color, gloss, hardness, etc. are selected depending on the material of 4, and the thickness is preferably 10 to 50 microns.

The back material 28 is made of nonwoven fabric, woven fabric, paper, vinyl chloride resin sheet, or the like. The main purpose of this back material 28 is to protect the back surface of the foam 24.

The ceiling material 0 thus formed is manufactured in the following manner using a split 40 mold having a cavity 42 in the shape of a product.

First, urethane paint is spray applied to the cavity surface 44 of one side 40a of the split mold 40 to form a coating film 26, and the backing material 28 is installed on the cavity surface 46 of the other side 40b.
Furthermore, a reinforcing material 30 is installed in the cavity 42 as required. Note that if the split mold 40b for mounting the backing material is provided with a vacuum suction hole that reaches the cavity surface 46, and if the backing material 28 is brought into close contact with the cavity surface 46 by vacuum suction, The back material 28 can be easily and reliably installed.

Next, the split mold 40 is closed and a raw material 50 for forming a foam having a dense layer on the surface, such as integral skin urethane foam, is injected into the cavity 42 through the injection port 48 . 5
2 is an injection device.

The injected raw material 50 foams and, if the reinforcing material 30 is present, surrounds the reinforcing material 30 to form a cavity-shaped foam. At this time, due to the adhesive properties of the foam forming raw material 50, the foam adheres to the coating film 26 and the backing material 28 and becomes an integral body. Then, when the molded product is taken out from the split mold 40, the automobile ceiling material 20 is obtained.

(Effects of the Invention) The automobile ceiling material according to the present invention has a structure in which a coating film is laminated on the surface of a foam having a dense layer on the surface, and a backing material is laminated on the other surface of the foam. Therefore, the pore structure of the foam made it possible to improve sound absorption, and the dense layer and coating on the surface of the foam made it possible to obtain the surface strength necessary for automobile ceiling materials.

In addition, the manufacturing method for automobile ceiling materials involves forming a coating film on one cavity surface of a split mold, installing a backing material on the other cavity surface, and installing or not installing a reinforcing material in the remaining cavity. In this method, raw materials for forming a foam having a dense layer on the surface are injected and foamed. Therefore, when foaming, the coating film and backing material do not stretch, sag, deform, etc., and do not cause wrinkles, making it possible to obtain an automotive ceiling material with a good appearance.

[Brief explanation of drawings]

Fig. 1 is a partial cross-sectional view of an example of an automobile ceiling material according to the present invention, Fig. 2 is a sectional view of a split type during manufacturing of the automobile ceiling material of the present invention, and Fig. 3 is a partial cross-sectional view of an example of an automobile ceiling material according to the present invention. FIG. 3 is a cross-sectional view of the press die and the like during manufacturing. 22 dense layer, 24 foam having a dense layer on the surface, 26 coating film, 28 backing material, 30 reinforcing material, 4
0 Split type, 42 Cavity, 44.46 Cavity surface, 48 Inlet, 50 Raw material for forming a foam with a dense layer on the surface Patent applicant Inoue MCP Co., Ltd. Figure 1

Claims (6)

[Claims] (1) A ceiling material for an automobile, comprising a foam having a predetermined shape and a dense layer on the surface, a paint film being laminated on the surface, and a backing material being laminated on the other side of the foam. (2) The automobile ceiling material according to claim 1, wherein the foam has a reinforcing material inside. (3) The automobile ceiling material according to claim 1 or 2, wherein the foam is made of integral skin urethane foam. (4) Foaming with a dense layer on the surface by forming a coating film on one cavity surface of a split mold, installing a backing material on the other cavity surface, and installing or not installing a reinforcing material in the remaining cavities. A method for producing a ceiling material for an automobile, which comprises injecting a material for forming a body, molding the foam, and integrating the foam, a coating film, and a backing material. (5) The method for manufacturing a ceiling material for an automobile according to claim 4, wherein the foam is an integral skin urethane foam. (6) A method for manufacturing a ceiling material for an automobile according to claim 4 or 5, in which the back material is applied to the cavity surface by vacuum suction.