WO2020235434A1 - Heat-insulating interior material, method for manufacturing heat-insulating interior material, and vehicle ceiling material comprising heat-insulating interior material - Google Patents

Abstract

Provided are a heat-insulating interior material, a method for manufacturing the heat-insulating interior material, and a vehicle ceiling material comprising the heat-insulating interior material that allow for the maintenance of high heat-insulating properties over a long period of time, are excellent in production yield, handling, and reliability, and are maintenance-free and lightweight. A heat-insulating material (20) comprises a vacuum heat-insulating material (27 or 28) and a foamed body (23). In the vacuum heat-insulating material, a core material molded body, in which a core material containing an inorganic powder is molded, is surrounded by an outer bag and is vacuum-sealed inside the outer bag. The foamed body is integrally layered so as to cover the vacuum heat-insulating material.

Description

Insulation interior member, manufacturing method of insulation interior member, and ceiling material for vehicles equipped with insulation interior member

The present invention relates to a heat insulating interior member, a method for manufacturing the heat insulating interior member, and a ceiling material for a vehicle provided with the heat insulating interior member.

In the summer, the outside air temperature is high and the sunlight is strong, so the cabin temperature rises, and in the winter, the outside air temperature is low, so the heat in the cabin leaks to the outside and the cabin temperature drops. As a countermeasure, a heat insulating member is attached from the passenger compartment side along the ceiling space of the vehicle. As a heat insulating member, a vacuum heat insulating material in which a foam (hard polyurethane foam) is covered is known. As the vacuum heat insulating material, a core material in which glass wool is flatly compressed into a sheet shape (plate shape) is sealed inside the outer bag under reduced pressure.

As a method of covering the vacuum heat insulating material with the foam, a glass wool vacuum heat insulating material is placed inside the mold, the space between the mold and the vacuum heat insulating material is filled with the foam mixed liquid, and the filled mixed liquid is filled. It is known to foam and cover the vacuum heat insulating material with foam. As a result, a flat heat insulating member in which the vacuum heat insulating material is covered with foam is formed. This heat insulating member is attached to the ceiling space of the vehicle from the vehicle interior side (Patent Document 1).
However, when the vacuum heat insulating material provided with the glass wool core material is attached to the ceiling space of the vehicle, gas leakage proceeds due to exposure to high temperature, and gas convection in the core material may reduce the heat insulating property. Further, the vacuum heat insulating material provided with the glass wool core material is difficult to be thinned, and weight reduction when it is attached to a vehicle is an issue. Further, the vacuum heat insulating material provided with the glass wool core material has room for improvement in terms of followability to the curved surface portion for effectively attaching to the curved surface portion of the vehicle.

Instead of the glass wool core material, a vacuum heat insulating material is made from a core material made by hardening inorganic powder with a binder, and a heat insulating member whose circumference is covered with a foam can be attached to the ceiling space of the vehicle from the passenger compartment side. It is known (Patent Document 2). If a core material containing an inorganic powder is used, gas convection due to a gas leak is unlikely to occur, so that the internal airtightness of the vacuum heat insulating material can be easily maintained for a long period of time.

However, since the heat insulating member described in Patent Document 2 is also formed into a flat and thick film shape, when the heat insulating member is attached to the ceiling space of the vehicle, the curved surface shape (particularly, particularly) forming the ceiling space of the vehicle is formed. It is difficult to follow the three-dimensional shape). For this reason, it takes time to attach the heat insulating member to the ceiling space of the vehicle, and there is room for improvement in terms of productivity.
Furthermore, since the foam covering the vacuum heat insulating material is exposed, the foam may be damaged during handling of the vacuum heat insulating material and the heat insulating performance of the vacuum heat insulating material may be impaired, and from the viewpoint of handleability. There is room for improvement.

Japanese Patent No. 4661670 International Publication No. 2014/087834

The present invention can follow the curved surface shape of the ceiling space of a vehicle, maintain high heat insulation performance for a long period of time, is excellent in productivity, handleability, and reliability, does not require maintenance, and is lightweight. Provided are a method for manufacturing a heat insulating interior member and a ceiling material for a vehicle provided with the heat insulating interior member.

The present invention has the following forms.
[1] The vacuum heat insulating material in which the core material molded body containing the inorganic powder is molded is surrounded by an outer bag and sealed under reduced pressure inside the outer bag, and the vacuum heat insulating material is covered. A heat insulating interior member having a foam that is integrally laminated and having a radius of curvature R of 10 mm or more in a state where the foam is integrally laminated.
[2] The heat insulating interior member according to [1], wherein the thickness of the vacuum heat insulating material is 5 mm or less.
[3] The heat insulating interior member according to [1] or [2], wherein the core material molded body has a density of 0.10 to 0.35 g / cm ³ .
[4] The number of the vacuum heat insulating materials installed is n (n is an integer of 1 or more), the developed area when the vacuum heat insulating material is deployed in the horizontal direction with respect to the installation surface is Sn, and the heat insulating interior member. When the area obtained by subtracting the area of the opening from the expanded area when deployed in the horizontal direction with respect to the installation surface is the allowable installation area Sx, the installation area ratio of the vacuum heat insulating material = (ΣSn / Sx) × 100. The heat insulating interior member according to any one of [1] to [3], which is 20% or more.
[5] The heat insulating interior member according to any one of [1] to [4], which further has sound absorbing properties.
[6] The heat insulating interior member according to any one of [1] to [5], wherein the foam contains a rigid polyurethane foam.
[7] The heat insulating interior member according to any one of [1] to [5], wherein the foam contains a semi-rigid polyurethane foam.
[8] The heat insulating interior member according to any one of [1] to [7], comprising a skin material integrally laminated so as to cover the upper surface and the lower surface of the foam.
[9] A step of molding a core material containing an inorganic powder to obtain a core material molded body, a step of enclosing the core material molded body under reduced pressure inside an outer bag, and a step of obtaining a vacuum heat insulating material. The vacuum heat insulating material is molded by a molding die according to the shape of the attached portion to which the vacuum heat insulating material is attached, and the foam is integrally molded so as to cover the molded vacuum heat insulating material. A method for manufacturing a heat insulating interior member including a step of laminating the heat insulating material.
[10] A vehicle ceiling material provided with the heat insulating interior member according to any one of [1] to [8].

According to the heat insulating interior member, the method for manufacturing the heat insulating interior member, and the ceiling material for a vehicle provided with the heat insulating interior member, the present invention can be applied to a curved surface such as a ceiling space of a vehicle, and high heat insulating performance can be maintained for a long period of time. It has excellent productivity, handleability, and reliability, and can eliminate maintenance. Further, as a result of thinning the heat insulating interior member itself, the weight of the heat insulating member can be reduced.

It is a perspective view which shows the vehicle provided with the heat insulating interior member of embodiment which concerns on this invention. It is a partially cutaway plan view which shows typically the state which the heat insulation interior member of embodiment was seen from the roof side. It is sectional drawing which follows the line III-III of FIG. It is a partial cross-sectional perspective view which shows the 1st vacuum heat insulating material of embodiment. It is sectional drawing which shows the V part of FIG. 3 enlarged. (A) is a cross-sectional view showing a step of placing the first skin material on the first fixed mold. (B) is a cross-sectional view showing a step of placing the first vacuum heat insulating material on the first skin material. (C) is a cross-sectional view showing a step of bending and molding the first vacuum heat insulating material laminated on the first skin material. (A) is a cross-sectional view showing a step of laminating a foam on the first vacuum heat insulating material. (B) is a cross-sectional view showing a step of laminating a second skin material on a foam. (C) is a cross-sectional view showing a step of taking out a heat insulating interior member from a first fixed mold.

Next, an embodiment of the present invention will be described with reference to the drawings. When viewed from the occupants of the vehicle, the front of the vehicle is indicated by FR, the rear of the vehicle by RR, the right side of the vehicle by RH, the left side of the vehicle by LH, and the upper part of the vehicle by UP.
Further, "-" indicating a numerical range means that the numerical values described before and after the numerical range are included as the lower limit value and the upper limit value.

As shown in FIG. 1, the vehicle 10 is provided with a heat insulating interior member 20 at a mounted portion (mounted portion) of the roof 12. In the embodiment, an example in which the heat insulating interior member 20 is provided on the ceiling material for a vehicle to be attached to the “roof 12” of the vehicle 10 will be described, but the attachment portion is not limited to the roof 12. As another example, the floor of the vehicle 10, the right front side door 13, the left front side door, the right rear side door 14, the left rear side door, the right rear fender 15, the left rear fender, the bonnet 16, and the rear lid 17 are vacuumed inside. Insulation material can also be attached. Further, the vehicle 10 is not limited to the passenger car as shown in FIG. 1, and may be a vehicle such as a truck, an industrial vehicle, or a railroad.
A heat insulating interior member 20 is attached to the roof 12 of the vehicle 10 from the vehicle interior 19 side (see FIG. 3).

(Insulated interior material)
As shown in FIGS. 2 and 3, the heat insulating interior member 20 includes a vacuum heat insulating portion 21, an adhesive layer 22, a foam 23, a first skin material (decorative member) 24, and a second skin material 25. , Is equipped.
The heat insulating interior member 20 is bent and molded to match the curved surface shape (shape) of the roof 12, for example, so that the entire area projects three-dimensionally upward in the vehicle width direction and the vehicle front-rear direction. There is. Further, in the heat insulating interior member 20, for example, the peripheral portion 20a is bent and molded in a curved shape with a radius of curvature smaller than that of other portions. In addition, the heat insulating interior member 20 has an overhanging portion 20b that projects outward from the peripheral portion 20a.

The vacuum heat insulating portion 21 includes a first vacuum heat insulating material 27 and a second vacuum heat insulating material 28 (see FIG. 2). The first vacuum heat insulating material 27 and the second vacuum heat insulating material 28 are primary molded into a flat sheet shape (plate shape), and further secondary molded according to the curved surface shape of the mounted portion 12x of the roof 12. ..
In the embodiment, an example in which the vacuum heat insulating material 21 is composed of the first vacuum heat insulating material 27 and the second vacuum heat insulating material 28 will be described, but the shape and number of the vacuum heat insulating materials can be appropriately selected.

(Vacuum heat insulating material)
As shown in FIG. 4, the first vacuum heat insulating material 27 includes a core material molded body 31 and an outer bag 32. The first vacuum heat insulating material 27 is a sheet-shaped (plate-shaped) heat insulating material that is surrounded by the core material molded body 31 being housed in the outer bag 32, is sealed under reduced pressure inside the outer bag 32, and is primarily molded. is there.
The thickness T1 of the first vacuum heat insulating material 27 is substantially the same as that of the core material molded body 31.
The core material molded body 31 contains an inorganic powder. The core material molded body 31 is formed by molding a mixture of a core material containing an inorganic powder and other components (described later) to be added as needed by press molding (compression molding), molding, or the like. The core material molded body 31 is usually molded into a plate-shaped sheet.

Examples of the inorganic powder include fumed silica, which is an extremely fine powder. Specific examples of fumed silica include Aerosil 200 (specific surface area 200 m ² / g, manufactured by Nippon Aerosil Co., Ltd.), Aerosil 300 (specific surface area 300 m ² / g, manufactured by Nippon Aerosil Co., Ltd.), CAB-O-SIL M- 5 (specific surface area 200 m ² / g, manufactured by Cabot Japan), CAB-O-SIL H-300 (specific surface area 300 m ² / g, manufactured by Cabot Japan), Leolosil QS30 (specific surface area 300 m ² / g, manufactured by Tokuyama) ).

Since fumed silica is an extremely fine powder, the specific surface area is usually used as an index for expressing the grain size.
The specific surface area of the fumed silica is preferably 50 ~ 400m ² / g, more preferably 100 ~ 350m ² / g, particularly preferably 200 ~ 300m ² / g. When the specific surface area of fumed silica is at least the above lower limit value, excellent heat insulating performance can be easily obtained.
The specific surface area in the present invention is measured by the nitrogen adsorption method (BET method).
Since the first vacuum heat insulating material 27 uses an extremely fine inorganic powder as a core material, gas convection due to a gas leak is unlikely to occur, and the heat insulating performance of the first vacuum heat insulating material 27 can be maintained for a long period of time.
As a result, the heat insulating interior member 20 can be maintained with high heat insulating performance for a long period of time, has excellent reliability, and can eliminate maintenance.

The core material molded body 31 may contain fibers. Examples of the fiber include the following inorganic fiber and / or organic fiber. Among them, the inorganic fiber is preferable because the gas component volatilizes less under vacuum, it is easy to suppress the deterioration of the heat insulating performance due to the decrease in the degree of vacuum, and the heat resistance is excellent.
Examples of the inorganic fibers include alumina fibers, mulite fibers, silica fibers, glass wool, glass fibers, rock wool, slag wool, silicon carbide fibers, carbon fibers, silica-alumina fibers, silica-alumina-magnesia fibers, and silica-alumina. -Zirconia fiber, silica magnesia calcia fiber can be mentioned. Of these, glass fiber, rock wool, or silica-magnesia-calcia fiber is preferable from the viewpoint of price, safety, and the like.
Examples of the organic fiber include nylon fiber, polyester fiber, vinylon fiber, wool fiber, and cotton fiber.
When the core material molded body 31 contains fibers, the content ratio of the fibers to 100 parts by mass of the total mass of the inorganic powder and the fibers is preferably 2 to 30 parts by mass.

The outer bag 32 is airtight and can be sealed with the core material molded body 31 under reduced pressure. Examples of the outer bag 32 include a bag made of a gas barrier film having excellent flexibility and high heat resistance. As the gas barrier film, known ones used for the vacuum heat insulating material can be used without limitation.
Specifically, the outer bag 32 includes a first outer cover material 34 and a second outer cover material 35. The first outer cover material 34 and the second outer cover material 35 are formed in a rectangular shape, for example. The first outer cover material 34 and the second outer cover material 35 are heat-welded to the three sides of the peripheral portion with a predetermined width dimension to form the welded portion 37. As a result, the first outer cover material 34 and the second outer cover material 35 form a bag-shaped outer bag 32 with a three-way seal. The welded portion 37 may be bent and used.
The width dimension W of the welded portion 37 is preferably 5 to 20 mm. Within this range, a decrease in the degree of vacuum can be suppressed during long-term use.

The core material molded body 31 is housed inside the outer bag 32 in which the three sides of the peripheral portion are heat-welded, and in this state, the outer bag 32 and the core material molded body 31 are installed in a vacuum chamber having a heat welding function. Will be done. The inside of the outer bag 32 is depressurized, and the remaining one side of the opened bag is heat-welded and sealed. That is, the core material molded body 31 is sealed under reduced pressure inside the outer bag 32. As a result, the first vacuum heat insulating material 27 is flatly molded into a sheet shape (plate shape) having a rectangular shape in a plan view by the outer bag 32 and the core material molded body 31.

The degree of vacuum inside the outer bag 32 of the first vacuum heat insulating material 27 is preferably 1 × 10 ³ Pa or less, preferably 5 × 10 ² Pa, from the viewpoint of excellent heat insulating performance and long life of the first vacuum heat insulating material 27. The following is more preferable, and 1 × 10 ² Pa or less is further preferable. The degree of vacuum inside the outer bag 32 is preferably 1 Pa or more, and more preferably 3 Pa or more, from the viewpoint that decompression inside the outer bag is easy.

As shown in FIGS. 2, 3 and 5, the first vacuum heat insulating material 27 is three-dimensionally directed upward in the vehicle width direction and the vehicle front-rear direction in accordance with the curved surface shape of the roof 12, for example. It is bent and molded so as to protrude. Further, in the first vacuum heat insulating material 27, for example, the left side portion 27a and the right side portion 27b are bent and molded in a curved shape with a radius of curvature smaller than that of other portions in the vehicle width direction.

In the first vacuum heat insulating material 27, for example, the density of the core material molded body 31 inside the outer bag 32 is preferably 0.10 to 0.35 g / cm ³ from the viewpoint of heat insulating properties and bending molding.
By setting the density of the core material molded body 31 to 0.10 g / cm ³ or more, the first vacuum heat insulating material 27 can be easily handled, and the powder can be less likely to be scattered when the vacuum heat insulating material 27 is sealed under reduced pressure. By setting the density of the core material molded body 31 to 0.35 g / cm ³ or less, the heat insulating performance is excellent.
By setting the density of the core material molded body 31 to 0.10 to 0.35 g / cm ^{3 in} this way, the shape retention of the core material molded body 31 is ensured, and the heat insulating property of the first vacuum heat insulating material 27 is improved. Can be planned. The density of the core material molded body 31 is more preferably 0.15 to 0.25 g / cm ³ .

The thickness T1 of the first vacuum heat insulating material 27 is preferably 5 mm or less, and more preferably 2 to 4 mm, from the viewpoint of handleability and heat insulating properties of the heat insulating interior member 20. Here, the thickness T1 refers to the thickness of the portion not including the bent portion when the welded portion 37 is bent and used.
Since the core material molded body 31 in the first vacuum heat insulating material 27 contains an inorganic powder, it can be easily molded into a thin shape. Therefore, the thickness T1 of the first vacuum heat insulating material 27 can be kept small. That is, the first vacuum heat insulating material 27 can be made lighter and thinner than the case where the conventional core material obtained by compressing glass wool or the like is used. As a result, the heat insulating interior member 20 can be made lightweight and thin, and the handleability of the heat insulating interior member 20 can be improved.

Further, when the core material molded body 31 further contains fibers, the core material molded body 31 does not need to include a binder because the fibers function as a reinforcing material for the core material molded body 31. Therefore, the heat insulating interior member 20 can be made lighter and thinner than the case where a conventional core material in which powder is coated with a binder is used.
According to the present invention, even when the thickness T1 of the first vacuum heat insulating material 27 is thin, specifically 5 mm or less, the thermal conductivity of the first vacuum heat insulating material 27 is, for example, 0.002 to. It can be suppressed to 0.005 W / mK as small as possible. As a result, the heat insulating property of the first vacuum heat insulating material 27 can be ensured.
Further, by setting the thickness T1 of the first vacuum heat insulating material 27 to 2 to 4 mm, the heat insulating interior member 20 can be made lighter and thinner while the thermal conductivity of the first vacuum heat insulating material 27 is kept small.

The first skin material 24 (described later) is laminated on the back surface of the first vacuum heat insulating material 27 (that is, the second outer cover material 35) via the adhesive layer 22. As a constituent material of the adhesive layer 22, a liquid or foamy adhesive is preferably used.
As the liquid adhesive, for example, an adhesive capable of controlling the pot life of curing by air oxidative curability, moisture curability, temperature sensitivity, catalytic reaction, etc., that is, the back surface adhesive of the first vacuum heat insulating material 27 is applied. However, when the adhesive is positioned and placed on the first skin material 24, the adhesive does not develop adhesive force, and the adhesive has the property of starting to cure over time through steps such as contact with air or moisture and heating. preferable. Examples of the adhesive whose pot life can be controlled include a room temperature curable adhesive containing an anaerobic polymerizable monomer having a (meth) acrylic group and a radical polymerization initiator as main components. Further, a thermosetting resin adhesive such as an epoxy adhesive or a urethane adhesive can also be used. The two liquids of the above adhesive may be used in combination to control the pot life of curing.
As the foam adhesive, it is preferable to use a mixed solution of foam. By using a mixed solution of foam as the foam adhesive, it is possible to absorb the strain caused by the difference in linear expansion coefficient between the first vacuum heat insulating material 27 and the first skin material 24, and the foam 23 described later. In the molding step, the mixed liquid wraps around between the first vacuum heat insulating material 27 and the first skin material 24, and the adhesive layer 22 can be formed at the same time.

The second vacuum heat insulating material 28 has the same configuration as the first vacuum heat insulating material 27, only the shape is different. Therefore, each component of the first vacuum heat insulating material 27 is designated by the same reference numeral as that of the first vacuum heat insulating material 27, and detailed description thereof will be omitted.

(Foam)
The foam 23 is integrally laminated so as to cover the first vacuum heat insulating material 27 and the second vacuum heat insulating material 28 (that is, the vacuum heat insulating portion 21). Hereinafter, in order to facilitate understanding of the configuration, the relationship between the first vacuum heat insulating material 27 and the foam 23 will be described, and the description of the relationship between the second vacuum heat insulating material 28 and the foam 23 will be omitted.

The foam 23 is formed so as to cover the upper surface (that is, the first outer cover material 34) and the peripheral edge 27c of the first vacuum heat insulating material 27. The upper surface of the foam 23 is a surface facing the inner surface of the roof 12. Examples of the foam 23 include rigid polyurethane foam and semi-rigid polyurethane foam.
The rigid polyurethane foam has, for example, open cells, and has heat insulating properties and sound absorbing properties. Examples of the rigid polyurethane foam include a rigid polyurethane foam obtained by reacting a polyether polyol and a polyisocyanate compound in the presence of a foaming agent, a foam stabilizer and a catalyst. In addition to the polyether polyol, a polyvalent hydroxyl group-containing compound such as a polyester polyol can also be used.

The open cell ratio of the rigid polyurethane foam having open cells is preferably 60% or more, more preferably 70% or more, and particularly preferably 80% or more. When the open cell ratio is equal to or higher than the lower limit, shrinkage of the rigid polyurethane foam is unlikely to occur.
The open cell ratio is measured by a method based on JIS K 7138.

Further, the core density of the rigid polyurethane foam is preferably 20 kg / m ³ or more from the viewpoint of shrinkage deformation, for example. By setting the core density of the rigid polyurethane foam to 20 kg / m ³ or more, it is possible to prevent the rigid polyurethane foam from undergoing shrinkage deformation. The core density of the rigid polyurethane foam is measured by a measuring method based on JIS K7222.

Further, instead of the open-cell hard polyurethane foam, for example, a closed-cell hard polyurethane foam can be used.
Further, as the foam 23, a semi-rigid polyurethane foam can be used instead of the rigid polyurethane foam. Semi-rigid polyurethane foam is an intermediate material between flexible polyurethane foam and rigid polyurethane foam. The semi-rigid polyurethane foam has open cells and is preferable in terms of heat insulation and sound absorption. The semi-rigid polyurethane foam preferably has a core density of 20 kg / m ³ or more, and an open cell ratio of 60% or more. When the core density and / or open cell ratio of the semi-rigid polyurethane foam is at least the lower limit, shrinkage of the semi-rigid polyurethane foam is unlikely to occur.

By covering the upper surface (first outer cover material 34) and the peripheral edge 27c of the first vacuum heat insulating material 27 with the foam 23, the first vacuum heat insulating material 27 can be reinforced by the foam 23. As a result, the shape of the first vacuum heat insulating material 27 can be maintained by the foam 23, and the handleability of the heat insulating interior member 20 can be improved.
Further, by covering the upper surface (first outer cover material 34) and the peripheral edge 27c of the first vacuum heat insulating material 27 with the foam 23, in addition to the heat insulating property of the first vacuum heat insulating material 27, the heat insulating property of the foam 23 is improved. Can be secured. As a result, the heat insulating property of the heat insulating interior member 20 can be further improved, and high heat insulating performance can be maintained for a long period of time.
Further, by covering the upper surface (first outer cover material 34) and the peripheral edge 27c of the first vacuum heat insulating material 27 with the foam 23 having sound absorbing property, sound absorbing property can be ensured as an additional function of the heat insulating interior member 20.

(Skin material)
The first skin material 24 is integrally laminated by the adhesive layer 22 on the back surface (second outer cover material 35) of the first vacuum heat insulating material 27. In other words, the first skin material 24 is integrally laminated on the adhesive layer 22 so as to cover the surface of the adhesive layer 22 on the side opposite to the attached portion 12x. That is, the first skin material 24 is a skin material that forms the back surface (backmost surface) of the heat insulating interior member 20. Examples of the first skin material 24 include those in which the backmost surface side of a sheet base material made of a material having excellent flexibility and high heat resistance is decorated. For example, the material of the sheet base material includes fiber reinforced plastic (FRP), hard plastic or its foam, and the decorative member includes moldable knit, fabric, suede-blended synthetic leather, polyvinyl chloride leather, and thermoplastic. Examples include an elastomer sheet. At this time, as the first skin material 24, a molded sheet in which the skin layer is integrated with the base material can also be used.

Further, the second skin material 25 is integrally laminated on the surface 23a on the side to be attached to the foam 23. That is, the second skin material 25 can be a skin that protects the surface (outermost surface) of the heat insulating interior member 20. Examples of the second skin material 25 include a sheet made of a thermoplastic resin having excellent flexibility and capable of pneumatic molding (molding using the pressure of compressed air). When the second skin material 25 is laminated on the surface of the foam 23 of the heat insulating interior member 20, decoration on the outermost surface is not required.

When the innermost surface of the heat insulating interior member 20 is formed of the first skin material 24 and the outermost surface of the heat insulating interior member 20 is formed of the second skin material 25, the first vacuum heat insulating material 27 is formed of the first skin material 24. It is covered, and the foam 23 is covered with the second skin material 25. As a result, the first vacuum heat insulating material 27 is protected by the first skin material 24, and the foam 23 is protected by the second skin material 25. Therefore, for example, the damage of the first vacuum heat insulating material 27 can be suppressed by the first skin material 24, and the damage of the foam 23 can be suppressed by the second skin material 25. As a result, the handleability of the heat insulating interior member 20 can be improved.
Further, the thickness T2 of the heat insulating interior member 20 is preferably 20 mm or less, more preferably 10 mm or less, for example, from the viewpoint of handleability of the heat insulating interior member 20.

Here, the heat insulating interior member 20 is integrally molded by laminating the first vacuum heat insulating material 27, the foam 23, the first skin material 24, and the second skin material 25. The radius of curvature R of the heat insulating interior member 20 is set to 10 mm or more from the viewpoint of corresponding to the attached portion 12x and the point of preventing damage to the outer bag 32. Further, the radius of curvature R of the heat insulating interior member 20 is more preferably 20 to 100 mm, further preferably 30 to 50 mm.
By setting the radius of curvature R of the heat insulating interior member 20 to 10 mm or more, for example, the heat insulating property of the first vacuum heat insulating material 27 can be maintained for a long period of time, is excellent in reliability, and maintenance can be eliminated.

Further, by setting the radius of curvature R of the heat insulating interior member 20 to 10 mm or more, for example, the heat insulating interior member 20 is bent and molded into a curved shape with a small radius of curvature corresponding to the peripheral portion 12a of the roof 12. Further, the heat insulating interior member 20 is bent and molded so as to conform to the curved surface shape of the roof 12, for example, so that the entire area projects three-dimensionally upward in the vehicle width direction and the vehicle front-rear direction. ..
Therefore, it is possible to correspond to various shapes of the attached portion 12x such as the roof 12 to which the heat insulating interior member 20 is attached. As a result, the heat insulating interior member 20 can be easily attached to various types of attached portions 12x. As a result, the time required for mounting the heat insulating interior member 20 can be shortened, and the productivity can be improved.

Here, the heat insulating interior member 20 is a region between the first vacuum heat insulating material 27 and the second vacuum heat insulating material 28, a region around the first vacuum heat insulating material 27, and a region around the second vacuum heat insulating material 28. The foam 23 is provided in the. As a result, the heat insulating interior member 20 is reinforced by the foam 23, and the handleability of the heat insulating interior member 20 can be improved.
Further, by reinforcing the heat insulating interior member 20 with the foam 23, it is not necessary to prepare the reinforcing members individually, but if further strength is required, the reinforcing members may be provided on the entire surface or a part thereof. ..

Further, in the heat insulating interior member 20, the first vacuum heat insulating material 27 and the second vacuum heat insulating material 28 are reinforced by the foam 23, and are bent and molded according to the shape of the attached portion 12x. Since the first vacuum heat insulating material 27 and the second vacuum heat insulating material 28 can be formed by following the shapes of various attached portions 12x, the construction can be performed without impairing the workability of the conventional heat insulating member. As a result, the time required for mounting the heat insulating interior member 20 can be shortened, and the productivity can be improved.

Hereinafter, the relationship between the installation area (expanded area) of the vacuum heat insulating portion 21 and the allowable installation area Sx of the heat insulating interior member will be described.
The number of installed vacuum heat insulating materials is n (n is an integer of 1 or more), and the deployed area when each vacuum heat insulating material is deployed in the horizontal direction with respect to the installation surface of each vacuum heat insulating material is Sn. In the example of FIG. 2, the developed area of the first vacuum heat insulating material 27 is S1, the developed area of the second vacuum heat insulating material 28 is S2, and the developed area of the vacuum heat insulating portion 21 is ΣSn = S1 + S2. Further, the allowable installation area of the heat insulating interior member is Sx.

The developed area S1 is the direction in which the first vacuum heat insulating material 27 is horizontal to the installation surface of the first vacuum heat insulating material 27 (LH direction, RH direction, FR direction and FR direction in FIGS. 1, 2, 3 and 5). It is the unfolded area when unfolded in the RR direction (the same applies hereinafter).
The unfolded area S2 is the unfolded area when the second vacuum heat insulating material 28 is unfolded in the horizontal direction with respect to the installation surface of the second vacuum heat insulating material 28.
The allowable installation area Sx is an area where the vacuum heat insulating portion 21 can be installed, and is an opening (opening area) from the deployed area when the contour shape of the heat insulating interior member 20 is developed in the horizontal direction with respect to the installation surface of the heat insulating interior member For example, it is an area excluding the development area of the window portion and the interior light installation portion 12b) (not shown).

Using the deployment area S1, the deployment area S2, and the installation allowable area Sx, the installation area ratio is calculated as (ΣSn / Sx) × 100.
The installation area ratio is preferably 20% or more, more preferably 20 to 90%. By setting the installation area ratio of the vacuum heat insulating portion 21 to 20% or more, for example, the vacuum heat insulating portion 21 (that is, the first vacuum heat insulating material 27) is placed above the occupant seated in the front seat (driver's seat, passenger seat). Can be arranged, and sufficient heat insulation of the occupants can be secured. On the other hand, by setting the installation area ratio to 90% or less, for example, the vacuum heat insulating portion 21 can be provided at a certain distance from the end portion of the mounted portion 12x. Therefore, for example, a space for arranging the foam 23 can be secured on the periphery of the vacuum heat insulating portion 21, and the vacuum heat insulating portion 21 can be protected by the foam 23. As a result, the heat insulating property of the vacuum heat insulating portion 21 can be maintained high for a long period of time.

For example, in the case of the embodiment shown in FIG. 2, in a state where the heat insulating interior member 20 is attached to the roof 12, for example, the first vacuum heat insulating material 27 is arranged above the front seat of the vehicle 10, and the second vacuum heat insulating material 28 is located above the rear seats of vehicle 10. In this case, the installed area ratio calculated was [(S1 + S2) / Sx] × 100 = about 48%.
Alternatively, depending on the vehicle type of the vehicle 10, it is conceivable to arrange the vacuum insulation portion 21 only above the front seat of the vehicle 10. In that case, the installation area ratio of the vacuum heat insulating portion 21 is preferably 20% or more.

In this way, the installation area, the number of installations, and the installation location of the vacuum insulation unit 21 can be selected according to the required heat insulation performance, and the application can be expanded.

(Manufacturing method of heat insulating interior parts)
Next, a method of manufacturing the heat insulating interior member 20 will be described with reference to FIGS. 6 and 7. Specifically, the first vacuum heat insulating material 27 and the second vacuum heat insulating material 28, which are formed into a flat sheet shape (plate shape) by the primary molding, are secondarily molded into a desired shape by a molding die (mold).
In the embodiment, as an example of the molding die, a step of manufacturing the heat insulating interior member 20 in the first stage to the fifth stage of the molding die 40 will be described below. The manufacturing method of the heat insulating interior member 20 is not limited to the manufacturing method shown below.
In FIGS. 6 and 7, the first vacuum heat insulating material 27 of the vacuum heat insulating parts 21 will be described as an example, and the description of the second vacuum heat insulating material 28 will be omitted.

In the first stage shown in FIG. 6A, the pre-molded first skin material 24 is placed along the molding surface 41a of the first fixed mold 41 provided in the molding mold 40.
Next, in the first stage shown in FIG. 6B, the first vacuum heat insulating material 27 is placed on the first skin material 24 on the first fixed mold 41 in a positioned state. At this time, it is preferable that the adhesive layer 22 is laminated in advance on the back surface of the first vacuum heat insulating material 27 facing the first skin material 24. At this time, the first vacuum heat insulating material 27 can be placed on the first skin material 24 in a state of being positioned by a robot or the like. In this state, the first fixed mold 41 is moved from the first stage to the second stage.

In the second stage shown in FIG. 6 (c), the first vacuum heat insulating material 27 is press-molded into the first skin material 24 by molding the first movable mold 42 provided in the molding mold 40. That is, the first movable mold 42 presses the first vacuum heat insulating material 27 and the adhesive layer 22 toward the first skin material 24 on the first fixed mold 41. At this time, the first vacuum heat insulating material 27 may be heated to a temperature of 80 ° C. or lower and press-molded. In a state where the first vacuum heat insulating material 27 and the adhesive layer 22 are blended with the first skin material 24, the first vacuum heat insulating material 27 and the adhesive layer 22 are pressure-bonded along the first skin material 24. Therefore, in a state where the first vacuum heat insulating material 27 is adhered to the first skin material 24 with the adhesive layer 22, the first vacuum heat insulating material 27 is integrally laminated on the first skin material 24. At the same time, the first vacuum heat insulating material 27 is bent and molded according to the curved surface shape of the inner surface of the first skin material 24.
In this state, the first fixed mold 41 is opened from the first movable mold 42, and the first fixed mold 41 is moved from the second stage to the third stage.

In the third stage shown in FIG. 7A, the second movable mold 43 provided in the molding mold 40 is molded into the first fixed mold 41. In the cavity 44 formed between the first fixed mold 41 (specifically, the first vacuum heat insulating material 27) and the second movable mold 43, a mixed solution of the foam 23 is passed through the runner 45 and the gate 46 and arrows. Fill as in A. The installation positions of the runner 45 and the gate 46 are not limited to the positions shown in FIG. 7A.
The foam mixture filled in the cavity 44 is foamed, and the foam 23 is integrally formed with the upper surface of the first vacuum heat insulating material 27 (that is, the first outer cover material 34) and the peripheral portion 24a of the first skin material 24. It is integrally molded by molding in a laminated state. Therefore, the foam 23 covers the upper surface (first outer cover material 34) and the peripheral edge 27c of the first vacuum heat insulating material 27.
In this state, the first fixed mold 41 to the second movable mold 43 are opened, and the first fixed mold 41 is moved from the third stage to the fourth stage.

In the fourth stage shown in FIG. 7B, the third movable mold 48 provided in the molding mold 40 is molded into the first fixed mold 41. A peripheral portion 25a of the second skin material 25 softened by heating is attached to the third movable type 48. Therefore, by molding the third movable mold 48 to the first fixed mold 41, the second skin material 25 is placed in a state of being positioned on the foam 23. The second skin material 25 is pneumatically molded by applying air pressure toward the foam 23 as shown by an arrow B on the mounted second skin material 25. As a result, the second skin material 25 is brought into close contact with the foam 23 along the foam 23, and the second skin material 25 is integrally laminated on the upper surface of the foam 23. At this time, the peripheral portion 25a of the second skin material 25 and the peripheral portion 24a of the first skin material 24 are also integrally laminated.
The heat insulating interior member 20 is formed by integrally laminating the second skin material 25 on the upper surface of the foam 23. In this state, the first fixed mold 41 to the third movable mold 48 are opened, and the first fixed mold 41 is moved from the fourth stage to the fifth stage.

In the fifth stage shown in FIG. 7C, the heat insulating interior member 20 is released from the first fixed mold 41, and the heat insulating interior member 20 is taken out from the first fixed mold 41. Next, of the peripheral portion 24a of the first skin material 24 and the peripheral portion 25a of the second skin material 25, the portion protruding from the cutting line 50 is trimmed. As a result, the manufacturing process of the heat insulating interior member 20 is completed.
In this way, the first vacuum heat insulating material 27 is press-molded on the first skin material 24 to be bent and molded in a integrally laminated state. Further, the foam 23 is integrally laminated on the first skin material 24 and the first vacuum heat insulating material 27 by molding. Further, the second skin material 25 is integrally laminated on the foam 23 by compressed air molding. That is, the first skin material 24, the first vacuum heat insulating material 27, the foam 23, and the second skin material 25 are integrally laminated in a short construction time by press molding, mold molding, compressed air molding, or the like. It can be done and productivity can be increased.

The technical scope of the present invention is not limited to the above-described embodiment, and various modifications can be made without departing from the spirit of the present invention.
For example, in the above-described embodiment, an example in which the first vacuum heat insulating material 27 and the second vacuum heat insulating material 28 are collectively provided as the vacuum heat insulating portion 21 in the heat insulating interior member 20 has been described, but the present invention is not limited to this. As another example, the heat insulating interior member may be provided with one or three or more vacuum heat insulating materials.

Further, in the above-described embodiment, an example in which the foam 23 covering the upper surface of the first vacuum heat insulating material 27 is molded by molding has been described, but the present invention is not limited to this. As another example, the foam 23 can be molded by hot press molding.

10 ... Vehicle 12 ... Roof 12x ... Attached part 20 ... Insulated interior member 23 ... Foam 24 ... 1st skin material 25 ... 2nd skin material 27 ... 1st vacuum heat insulating material 28 ... 2nd vacuum heat insulating material 31 ... Core material Molded body 32 ... Outer bag 40 ... Molded mold The entire contents of the specification, claims, drawings and abstract of Japanese Patent Application No. 2019-096876 filed on May 23, 2019 are quoted here. However, it is incorporated as a disclosure of the specification of the present invention.

Claims (10)

1. A vacuum heat insulating material in which a core material molded body in which a core material containing an inorganic powder is molded is surrounded by an outer bag and sealed under reduced pressure inside the outer bag.
   With the foam integrally laminated so as to cover the vacuum heat insulating material,
   A heat-insulating interior member having a radius of curvature R of 10 mm or more in a state where the foams are integrally laminated.
2. The thickness of the vacuum heat insulating material is 5 mm or less.
   The heat insulating interior member according to claim 1.
3. The density of the core material molded product is 0.10 to 0.35 g / cm ³ .
   The heat insulating interior member according to claim 1 or 2.
4. The number of the vacuum heat insulating materials installed is n (n is an integer of 1 or more).
   The unfolded area when unfolded in the horizontal direction with respect to the installation surface of the vacuum heat insulating material is Sn.
   When the area obtained by subtracting the area of the opening from the deployed area when deployed in the horizontal direction with respect to the installation surface of the heat insulating interior member is defined as the allowable installation area Sx
   The installation area ratio of the vacuum heat insulating material = (ΣSn / Sx) × 100 is 20% or more.
   The heat insulating interior member according to any one of claims 1 to 3.
5. It also has sound absorption,
   The heat insulating interior member according to any one of claims 1 to 4.
6. The heat insulating interior member according to any one of claims 1 to 5, wherein the foam contains a rigid polyurethane foam.
7. The heat insulating interior member according to any one of claims 1 to 5, wherein the foam contains a semi-rigid polyurethane foam.
8. A skin material integrally laminated so as to cover the outermost surface and the outermost surface of the foam was provided.
   The heat insulating interior member according to any one of claims 1 to 7.
9. The process of molding a core material containing inorganic powder to form a core material molded body,
   The step of obtaining the vacuum heat insulating material by enclosing the core material molded body under reduced pressure inside the outer bag, and
   A step of molding the vacuum heat insulating material with a molding die according to the shape of the attached portion to which the vacuum heat insulating material is attached.
   A step of laminating the foam on the vacuum heat insulating material by integrally molding the foam so as to cover the molded vacuum heat insulating material.
   A method for manufacturing a heat insulating interior member, which comprises.
10. A vehicle ceiling material provided with the heat insulating interior member according to any one of claims 1 to 8.

Images