JP2007176474A - Exterior material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an exterior material making reduction performance of noise suitable and capable of giving rigidity capable of withstanding to weight increase by water absorption. <P>SOLUTION: A fender liner 14, i.e., the exterior material, has a surface layer 21, the outermost layer; and an inner layer 22 arranged between the surface layer 21 and an outer surface 13a of a tire house 13. The inner layer 22 is constituted by a first layer 22a and a second layer 22b. The surface layer 21, the first layer 22a and the second layer 22b are formed from non-woven fabric respectively. Further, the second layer 22b is formed from non-woven fabric obtained by a span bond method, thereby, tensile strength of the inner layer 22 is enhanced more than the surface layer 21. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to an exterior material that is attached on an outer surface of a lower body part of a vehicle such as a fender liner or an under protector.

  In general, exterior parts such as fender liners and under protectors are attached to the lower part of the vehicle body to prevent damage to the body due to rainwater, mud, etc. Yes. This exterior material has been made hard using synthetic resin, synthetic rubber, or the like as a material from the viewpoint of ensuring rigidity sufficient to withstand stains, scratches, and the like. However, such a hard exterior material generates a collision sound when rainwater, mud, gravel, pebbles or the like hits the exterior material. And such a collision sound will be propagated as a noise into a vehicle interior. In addition to such a collision sound, pattern noise may be mentioned as a sound that is propagated as noise into the vehicle interior. “Pattern noise” refers to noise (friction noise) generated when a tire tread (a portion in contact with the road surface) is in contact with the road surface.

  Thus, for example, Patent Documents 1 to 3 disclose an exterior material made of a sheet-like molded body including a nonwoven fabric in order to reduce the propagation of noise such as collision noise and pattern noise into the vehicle interior. The non-woven fabric is formed by a method of physically entwining a large number of fibers or binding a large number of fibers by binding with a binder. The exterior material which consists of a sheet-like molded object containing such a nonwoven fabric has the minute space (cell) enclosed by the entangled fibers. Since the cell exhibits a sound absorbing effect, pattern noise, impact sound, and the like are absorbed, so that the propagation of noise into the vehicle interior is reduced.

On the other hand, in exterior materials including nonwoven fabrics as in Patent Documents 1 to 3, moisture such as rainwater and snow enters and is taken into cells provided to exhibit a sound absorption effect, so that the exterior material absorbs moisture. May end up. Since the exterior material that has absorbed moisture in this way will increase in weight by its moisture absorption, it will not be able to withstand the increased weight, and its shape will change and bend, and the mounting strength will decrease. There is a risk of falling off the vehicle body. That is, the exterior material including the nonwoven fabric has a problem that the rigidity at the normal time such as when drying is sufficient, but the rigidity is insufficient to withstand the increase in weight at the time of water absorption. Therefore, in Patent Document 1, a water-repellent part is provided, and the exterior material is configured to prevent moisture from adhering to the surface thereof, thereby suppressing an increase in weight due to water absorption.
JP 2004-142675 A JP 2004-299626 A JP 2004-359066 A

  However, in the case of an exterior material including a non-woven fabric as described above, even if a water repellent part is provided as in Patent Document 1, moisture may be absorbed. That is, if it is the water | moisture content which adhered temporarily to the surface of an exterior material, the weight increase by water absorption can be suppressed suitably by providing a water-repellent part. However, the water-repellent part cannot suppress even moisture that collides with the exterior material vigorously, such as moisture splashed by the tire, or moisture that remains attached to the exterior material. In addition, there is a method in which the cell is blocked if it is possible to completely prevent even such water absorption, but in this case, the sound absorbing effect by the cell is not exhibited, and the tip falls. Therefore, in the exterior material including the nonwoven fabric, the noise reduction performance due to the sound absorption effect exhibited by the cell and the suppression performance of weight increase due to water absorption into the cell are not necessarily compatible, and the design of the exterior material is difficult. I was supposed to.

  The present invention has been made paying attention to such problems existing in the prior art. An object of the invention is to provide an exterior material capable of imparting rigidity capable of withstanding an increase in weight due to water absorption while making noise reduction performance suitable.

  In order to achieve the above object, an exterior material invention according to claim 1 is an exterior material that has a shape corresponding to at least a part of a lower body portion of a vehicle and is attached to an outer surface of the lower body portion. And when mounted on the outer surface of the lower part of the body, the outer layer has a surface layer disposed on the outermost layer, and an inner layer disposed between the surface layer and the lower part of the body, and the surface layer and the inner layer are respectively Is formed from a nonwoven fabric formed by forming a large number of fibers into a sheet shape, and the gist is that the nonwoven fabric forming the inner layer has higher tensile strength than the nonwoven fabric forming the surface layer.

  According to the above configuration, the exterior material has a laminated structure formed by laminating at least the surface layer and the inner layer, and is mounted on the outer surface of the lower part of the body so that the surface layer is disposed in the outermost layer. . Since each of these surface layers and inner layers is formed of a nonwoven fabric, each has a large number of minute spaces (cells) surrounded by fibers. Demonstrates reduced performance. In addition, since the surface layer is disposed on the outermost layer, the water splashed by the tire is likely to collide and the moisture is likely to remain attached, so that it is easier to absorb moisture than the inner layer. On the other hand, the inner layer has higher tensile strength than the surface layer that easily absorbs water. For this reason, even if the surface layer absorbs moisture, the weight increases, and the shape of the inner layer with increased tensile strength is about to change its shape, even if it tries to change its shape by bending or the like. Resists the force and suppresses the shape change of the exterior material accompanying the shape change of the surface layer. As a result, it is possible to provide rigidity that can withstand the increase in weight due to water absorption by increasing the tensile strength of the inner layer rather than the surface layer while making the noise reduction performance suitable by the sound absorption effect by the cell.

It invention of the outer package according to claim 2 is the invention according to claim 1, the nonwoven fabric forming the surface layer, the fiber density of 0.05 g / cm ³ or more and 0.95 g / cm ³ or less Is the gist.

  According to the said structure, the rigidity which can fully endure collision (chipping) etc. of earth and sand, a pebble, water, etc. can be provided to a surface layer. Therefore, by disposing the surface layer as the outermost layer, the exterior material can exhibit durability that can sufficiently withstand chipping and the like.

The gist of the invention of the exterior material according to claim 3 is that, in the invention according to claim 1 or claim 2, the nonwoven fabric forming the surface layer has a fiber diameter of 5 μm or more and 20 μm or less.
According to the above configuration, in the surface layer, since a cell having a size sufficient to exert a sufficient sound absorbing effect between the fibers can be formed, the noise reduction performance can be suitably maintained, and the nonwoven fabric can be formed. Since the fibers can be made difficult to cut, the durability performance can be suitably exhibited.

  The invention of the exterior material according to claim 4 has an air layer arranged between the inner layer and the lower part of the body in the invention according to any one of claims 1 to 3. The gist.

According to the above configuration, the air layer provided between the inner layer and the lower part of the body exhibits a sound absorbing effect, so that the noise reduction performance can be improved.
The invention of the exterior material according to claim 5 is the invention according to any one of claims 1 to 4, wherein the nonwoven fabric forming the inner layer has an elongation of less than 20%, and The gist is to include a fiber material having a tensile strength of 6 g / d to 10 g / d.

  According to the said structure, the nonwoven fabric which forms an inner layer contains the fiber material whose elongation is less than 20% and whose tensile strength is 6 g / d or more and 10 g / d or less. By including the fiber material, a suitable tensile strength that can resist a change in the shape of the surface layer can be imparted to the inner layer.

  The invention of the exterior material according to claim 6 is the invention according to any one of claims 1 to 4, wherein the inner layer includes at least two layers of a first layer and a second layer. Each of the first layer and the second layer is formed of a nonwoven fabric, and the nonwoven fabric forming the second layer has an elongation of less than 20% and is tensile. The gist is to include a fiber material having a strength of 6 g / d to 10 g / d.

  According to the said structure, the nonwoven fabric which forms a 2nd layer contains the fiber material whose elongation is less than 20% and whose tensile strength is 6 g / d or more and 10 g / d or less. By including the fiber material, a suitable tensile strength that can resist a change in the shape of the surface layer can be imparted to the second layer of the inner layer. Furthermore, the inner layer has a multi-layer structure, and by imparting tensile strength to the second layer, for example, suitable sound absorbing performance can be imparted to the first layer. it can.

  The invention of the exterior material according to claim 7 is the invention according to any one of claims 1 to 4, wherein the inner layer includes at least two layers of a first layer and a second layer. The first layer and the second layer are each formed of a nonwoven fabric, and the second layer is made of a nonwoven fabric obtained by a spunbond method.

  According to the said structure, the nonwoven fabric obtained by the spun bond method is used for the 2nd layer. The nonwoven fabric obtained by this spunbonding method has a high adhesion effect because the bonding points for bonding the fibers forming the nonwoven fabric are large, and the fibers and the bonding points restrain each other and restrain displacement of each other. It has the hardness that can give a feeling of elasticity (elasticity) and has the advantage that the shape is not easily broken. Therefore, a suitable tensile strength that can resist the change in shape of the surface layer can be imparted to the second layer of the inner layer. Furthermore, the inner layer has a multi-layer structure, and by imparting tensile strength to the second layer, for example, suitable sound absorbing performance can be imparted to the first layer. it can.

  The invention of the exterior material according to claim 8 is defined in JIS L 1085: 1998 as a state in which the surface layer and the first layer and the second layer of the inner layer are laminated in the invention according to claim 7. The gist is that the tensile strength measured by the non-woven fabric bonding test method is 1500 N or more in the vertical direction and 1700 N or more in the horizontal direction.

According to the said structure, the tensile strength (rigidity) of an exterior material can be favorably able to endure the weight increase by water absorption.
The invention of the exterior material according to claim 9 is the invention according to any one of claims 6 to 8, wherein the inner layer has the first layer on the surface layer side, and the second layer has The gist of the invention is that it is arranged on the outer surface side of the lower part of the body.

  In the above configuration, the second layer has a hardness capable of imparting a suitable tensile strength, as described above. On the other hand, since the surface layer is disposed in the outermost layer, it is preferable that the surface layer is given hardness (rigidity) that can sufficiently withstand chipping and the like. Therefore, when hardness is given to the surface layer, in the three layers of the surface layer, the first layer, and the second layer, the surface layer and the second layer having the hardness are arranged to face each other with the first layer interposed therebetween. These three layers have a so-called exoskeleton structure. And the rigidity of an exterior material can be made suitable because a surface layer and a 2nd layer exhibit the function of what is called a beam with respect to a 1st layer.

  The invention of the exterior material according to claim 10 is the invention according to any one of claims 6 to 9, wherein the nonwoven fabric forming the second layer is compared to the nonwoven fabric forming the surface layer, The gist is that the fiber density is the same or low.

According to the said structure, in a 2nd layer, the cell of a magnitude | size sufficient to exhibit sufficient sound absorption effect between fibers can be formed.
The invention of the exterior material according to claim 11 is the invention according to any one of claims 6 to 10, wherein the nonwoven fabric forming the second layer has a fiber density of 0.01 g / cm ^3. The gist is that it is 0.95 g / cm ³ or less.

  According to the above configuration, in the second layer, since a cell having a size sufficient to exert a sufficient sound absorbing effect between the fibers can be formed, the noise reduction performance can be suitably maintained. Since the fibers of the nonwoven fabric can be made difficult to break, the tensile strength can be made suitable.

  The invention of the exterior material according to claim 12 is the invention according to any one of claims 6 to 11, wherein the nonwoven fabric forming the first layer is more than the nonwoven fabric forming the surface layer. The gist is that the fiber density is lowered.

According to the said structure, in a 1st layer, the cell of the magnitude | size sufficient to exhibit sufficient sound absorption effect between fibers can be formed suitably.
The invention of the exterior material according to claim 13 is the invention according to any one of claims 6 to 12, wherein the nonwoven fabric forming the first layer has a fiber density of 0.005 g / cm ^3. The gist is that it is 0.5 g / cm ³ or less.

  According to the above configuration, in the first layer, since a large number of cells can be formed so as to have a sufficient sound absorbing effect between the fibers, the first layer mainly has a sound absorbing performance. By exhibiting, the noise reduction performance can be improved.

  The invention of the exterior material according to claim 14 is the invention according to any one of claims 6 to 13, wherein the nonwoven fabric forming the first layer is more than the nonwoven fabric forming the surface layer. The gist is that the fiber diameter is increased.

  According to the above configuration, it is possible to make it difficult to cut the fibers of the nonwoven fabric while forming a large number of cells to such an extent that a sufficient sound absorbing effect can be exhibited, so that the durability performance of the exterior material can be suitably maintained. it can.

  The invention of the exterior material according to claim 15 is the invention according to any one of claims 6 to 14, wherein the nonwoven fabric forming the first layer has a fiber diameter of 10 μm or more and 50 μm or less. It is a summary.

According to the said structure, in the 1st layer, the durable performance of an exterior | packing material can be maintained favorable, forming many cells which can exhibit a favorable sound absorption effect between fibers.
The invention of the exterior material according to claim 16 is the invention according to any one of claims 1 to 4, wherein the nonwoven fabric forming the inner layer includes a binder for bonding fibers together. The gist of the invention is to use a composite fiber obtained by combining and spinning at least two thermoplastic resins having different melting points.

  According to the said structure, the nonwoven fabric obtained by adhere | attaching fibers with the binder which consists of composite fibers is used for the inner layer. Since the nonwoven fabric using the binder made of the composite fiber has many adhesion points for bonding the fibers together, the fibers are suitably restrained at a large number of adhesion points, and the positional deviation between the fibers can be satisfactorily suppressed. It has a hardness that can give a firm feeling (tension feeling) and has an advantage that the shape is not easily broken. Therefore, it is possible to give the inner layer a suitable tensile strength that can resist the change in shape of the surface layer.

  The invention of the exterior material according to claim 17 is the invention according to claim 16, wherein the outer layer and the inner layer are laminated and measured by a nonwoven fabric test method defined in JIS L 1085: 1998. The gist is that the tensile strength is 1400 N or more in the vertical direction and 1800 N or more in the horizontal direction.

According to the said structure, the tensile strength (rigidity) of an exterior material can be favorably able to endure the weight increase by water absorption.
The invention of the exterior material according to claim 18 is the invention according to claim 16 or claim 17, wherein the nonwoven fabric forming the inner layer has a lower fiber density than the nonwoven fabric forming the surface layer. And

According to the said structure, the cell of a magnitude | size sufficient to exhibit sufficient sound absorption effect between fibers can be formed suitably in an inner layer.
The invention of the exterior material according to claim 19 is the invention according to any one of claims 16 to 18, wherein the nonwoven fabric forming the inner layer has a fiber density of 0.005 g / cm ³ or more, The gist is that it is 0.5 g / cm ³ or less.

  According to the above configuration, in the inner layer, since a large number of cells can be formed so as to have a sufficient sound absorbing effect between the fibers, the inner layer mainly exhibits sound absorbing performance. The noise reduction performance can be improved.

  The invention of the exterior material according to claim 20 is the invention according to any one of claims 16 to 19, wherein the nonwoven fabric forming the inner layer has a fiber diameter smaller than that of the nonwoven fabric forming the surface layer. The main point is to make this thicker.

  According to the above configuration, it is possible to make it difficult to cut the fibers of the nonwoven fabric while forming a large number of cells to such an extent that a sufficient sound absorbing effect can be exhibited, so that the durability performance of the exterior material can be suitably maintained. it can.

  The invention of the exterior material according to claim 21 is the invention according to any one of claims 16 to 20, wherein the nonwoven fabric forming the inner layer has a fiber diameter of 10 μm or more and 50 μm or less. Is the gist.

According to the said structure, the durable performance of an exterior material can be maintained favorable, forming in the inner layer many cells which can exhibit a favorable sound absorption effect between fibers.
The invention of the exterior material according to claim 22 is the invention according to any one of claims 1 to 21, wherein the exterior of the lower part of the body is formed along the outer surface of the tire house. The gist is to be configured as a fender liner for covering the outer surface of the tire house.

  According to the above configuration, in a tire house where chipping is likely to occur and noise is more likely to invade, the fender liner formed from a nonwoven fabric exhibits sound absorption performance while withstanding chipping. Improvements can be made.

  ADVANTAGE OF THE INVENTION According to this invention, the rigidity which can endure the weight increase by water absorption can be provided, making noise reduction performance suitable.

(First embodiment)
Hereinafter, a first embodiment in which the exterior material of the present invention is embodied in a fender liner will be described.
FIG. 1 is a schematic view showing a state in which a fender liner is attached to a vehicle. In the front part of the vehicle 11, a tire house 13 for housing the tire 12 is provided below the fender 11 a constituting the body. The tire house 13 is opened in the vehicle downward direction and the vehicle lateral direction (perpendicular to the paper surface), and is arranged so that the outer surface 13a faces the road surface 12a. A fender liner 14 is attached to the outer surface 13 a of the tire house 13. The fender liner 14 covers the outer surface 13a of the tire house 13 to protect the outer surface 13a from being damaged by pebbles, mud, gravel, rainwater, ice blocks (snow), etc. that the tire 12 jumps up from the road surface 12a. Yes. Further, the fender liner 14 has an impact sound (chipping noise) generated by pebbles and the like colliding with the outer surface 13a, a rubbing sound (pattern noise) generated by contact between the road surface 12a and the tire 12 during traveling of the vehicle 11, and a muffled sound. By exhibiting noise reduction performance that reduces noise such as (road noise), it contributes to the improvement of quiet performance in the passenger compartment.

  2 and 3 are perspective views showing the fender liner 14 as viewed from the outside and inside of the vehicle 11, respectively. The fender liner 14 is formed by forming the sheet material 15 along the outer surface 13 a of the tire house 13 so as to have a shape corresponding to the tire house 13. A plurality of mounting holes 16 are formed through the outer edge portion of the fender liner 14. The fender liner 14 is fixed to the tire house 13 by fitting or screwing pins, screws, or the like to the tire house 13 through these mounting holes 16. A suspension hole 17 for accommodating a suspension (not shown) that supports the tire 12 is provided in the center of the fender liner 14. The suspension hole 17 prevents the fender liner 14 and the suspension from coming into contact with each other, thereby suppressing the generation of noise such as a scratching sound caused by the fender liner 14 coming into contact with the suspension.

  A bead 18 projects from the surface (inner surface) of the fender liner 14. The bead 18 is constituted by two ridges formed by protruding the inner surface of the fender liner 14 toward the outer surface 13a of the tire house 13 in a U shape. The bead 18 reinforces the fender liner 14, thereby contributing to improvement in the rigidity of the fender liner 14. Further, when the fender liner 14 is attached to the tire house 13, the bead 18 has its surface brought into contact with the outer surface 13 a of the tire house 13, so that most of the inner surface of the fender liner 14 is removed from the outer surface 13 a of the tire house 13. Separate. In this way, the bead 18 is used to form an air layer 19 between the inner surface and the outer surface 13a of the tire house 13 by separating most of the inner surface of the fender liner 14 from the outer surface 13a of the tire house 13. (See FIG. 4).

  FIG. 4 is a schematic diagram showing a cross-sectional structure of the fender liner 14 taken along the line 4-4 in FIG. The fender liner 14 has a laminated structure in which a layer made of a sheet material 15 and the air layer 19 are laminated. Further, the sheet material 15 has a laminated structure in which a plurality of layers are laminated. In the present embodiment, the sheet material 15 has a laminated structure in which three layers are laminated. That is, when the fender liner 14 is mounted on the outer surface 13 a of the tire house 13, the sheet material 15 includes a surface layer 21 that constitutes the outermost layer of the fender liner 14, and the surface layer 21 and the outer surface 13 a of the tire house 13. And an inner layer 22 disposed therebetween. Further, the inner layer 22 has a first layer 22 a disposed on the surface layer 21 side and a second layer 22 b disposed on the outer surface 13 a side of the tire house 13. Each of the surface layer 21, the first layer 22a, and the second layer 22b is formed using a nonwoven fabric as a material. The fender liner 14 is a surface layer 21, which is a layer made of the sheet material 15, a first layer 22 a and a second layer 22 b, and air disposed between the second layer 22 b and the outer surface 13 a of the tire house 13. The layer 19 has a laminated structure in which four layers are laminated.

Next, each layer constituting the fender liner 14 will be described in detail.
First, the surface layer 21 constituting the outermost layer of the fender liner 14 will be described. The surface layer 21 is provided mainly for the purpose of improving the rigidity (hardness) of the fender liner 14 so that the fender liner 14 can withstand chipping. Further, noise such as chipping noise, pattern noise, road noise and the like is first propagated from the surface layer 21 to the fender liner 14. For this reason, the surface layer 21 is provided with sound absorbing performance in order to reduce the noise.

  The surface layer 21 is composed of a large number of first fibers 23 and a binder 24. The first fiber 23 is a main fiber of a nonwoven fabric that forms the surface layer 21. The binder 24 is for bonding the first fibers 23 to each other. The surface layer 21 has a network structure by causing the first fibers 23 bonded to each other by the binder 24 to be entangled with each other. A large number of cells 25, which are extremely small spaces surrounded by the first fibers 23, are formed inside the surface layer 21 having a network structure. That is, the surface layer 21 is configured as a so-called “aggregate of cells 25”. And when these cells 25 each exhibit a sound-absorbing effect, the surface layer 21 exhibits the function to reduce noise.

  The first fibers 23 are short fibers made of synthetic fibers. In this embodiment, polyethylene (PE) fiber is used. In addition, short fibers include those formed as short fibers (staples) at the time of spinning, and short fibers (staple fibers) formed by cutting long fibers. In the first fiber 23 of the present embodiment, used sheet skins, door panel skins, etc. can be reused, and waste materials made from fibers (recycled materials) from the viewpoint of reducing manufacturing costs. ) Is used.

  The fiber diameter of the first fiber 23 is preferably 5 μm or more and 20 μm or less from the viewpoint of suitably maintaining the noise reduction performance while improving the rigidity of the fender liner 14. When the fiber diameter of the first fiber 23 is less than 5 μm, the rigidity of the surface layer 21 may be reduced due to the reason that the first fiber 23 is easily cut. On the other hand, when the fiber diameter of the first fiber 23 exceeds 20 μm, it becomes difficult to form a space (cell 25) between the first fibers 23 entangled with each other, or the cell 25 is blocked by the other first fibers 23. The noise reduction performance may be deteriorated due to peeling or the like.

  For the binder 24, short fibers made of a thermoplastic resin having a lower melting point than the first fibers 23 are used. As the binder 24 of the present embodiment, a single fiber (filament) obtained by spinning a thermoplastic resin having a low melting point is used. As the filament, polyolefin fiber, polyester fiber such as polyethylene terephthalate (PET), and polystyrene fiber are preferably used because they are easily available and inexpensive. In the present embodiment, a filament made of polypropylene (PP) fiber, which is a polyolefin fiber, is used as the binder 24.

  The thermoplastic resin used for the binder 24 preferably has a melting point that is 20 ° C. or lower than the melting point of the first fibers 23. When the difference between the melting point of the first fiber 23 and the melting point of the binder 24 is less than 20 ° C., it becomes difficult to melt only the binder 24, and the noise reduction performance is lowered by the molten binder 24 blocking the cells 25. There is a risk that.

  Specifically, the melting point of the thermoplastic resin used for the binder 24 is preferably 80 to 170 ° C, more preferably 100 to 170 ° C. When the melting point is less than 80 ° C., the binder 24 is softened by heat applied from the body of the vehicle 11 (for example, engine heat), and the fender liner 14 may be deformed. On the other hand, when the melting point exceeds 170 ° C., it becomes difficult to form the fender liner 14 and the workability may be deteriorated.

  The fiber diameter of the filament used for the binder 24 is preferably 10 μm or more and 50 μm or less from the viewpoint of suitably maintaining the noise reduction performance while improving the rigidity of the fender liner 14. When the fiber diameter is less than 10 μm, the durability performance of the fender liner 14 may be deteriorated. On the other hand, when the fiber diameter exceeds 50 μm, the binder 24 may block the cell 25 and the noise reduction performance may be deteriorated.

  The fiber lengths of the first fibers 23 and the binder 24 are preferably 10 to 100 mm. When the fiber length is less than 10 mm, even if the fibers are entangled with each other, the cells 25 are not sufficiently formed, the noise reduction performance is reduced, or the entanglement between the fibers becomes insufficient. There is a risk that the durability performance may decrease. In addition, when the fiber length exceeds 100 mm, the noise reduction performance may be deteriorated due to an excessive increase in the fiber density of the first fibers 23.

The nonwoven fabric forming the surface layer 21 has an increased fiber density from the viewpoint of improving the rigidity (hardness) of the fender liner 14. That is, the rigidity (hardness) of the surface layer 21 is increased by increasing the fiber density and closely packing the fibers (first fibers 23). Specifically, the fiber density of the nonwoven fabric forming the surface layer 21 is preferably 0.05 g / cm ³ or more and 0.95 g from the viewpoint of suitably maintaining the durability performance while suitably exhibiting the noise reduction performance. / Cm ³ or less. When the fiber density is less than 0.05 g / cm ³ , there is a possibility that sufficient hardness that can suitably withstand chipping cannot be obtained. On the other hand, when the fiber density exceeds 0.95 g / cm ³ , the fibers are excessively clogged, and there is a possibility that the cells 25 that can sufficiently exhibit the noise reduction performance may not be formed.

In the nonwoven fabric forming the surface layer 21, the basis weight is preferably 100 g / m ² or more and 500 g / m ² or less from the viewpoint of suitably maintaining the noise reduction performance while improving the rigidity of the fender liner 14. More preferably, it is 200 g / m ² or more and 300 g / m ² or less. Further, the thickness dimension of the surface layer 21 is preferably 0.3 mm or more and less than 8 mm, more preferably 0.5 mm or more and 5 mm or less, and further preferably 0.5 mm or more, from the same viewpoint as the basis weight. 2 mm or less. When the basis weight is less than 100 g / m ² or the thickness dimension is 8 mm or more, the fiber density is excessively lowered, and the surface layer 21 may not be able to have a desired rigidity (hardness). There is also a risk of intrusion. On the other hand, when the basis weight exceeds 500 g / m ² or the thickness dimension is less than 0.3 mm, the fiber density of the nonwoven fabric forming the surface layer 21 is excessively increased, and the cell can sufficiently exhibit the noise reduction performance. 25 may not be formed.

  Furthermore, since the surface layer 21 is disposed in the outermost layer of the fender liner 14, it is preferable to impart water repellency because moisture easily adheres. Examples of a method for imparting water repellency to the surface layer 21 include a method of applying a water repellency imparting agent to the surface of the first fiber 23 and applying or impregnating a water repellency imparting agent to the nonwoven fabric forming the surface layer 21. Examples of the water repellency-imparting agent include silicone rubber. Further, when a recycled material is used for the first fiber 23, for example, some vehicle parts such as a seat skin and a door panel skin are provided with water repellency as desired. For this reason, it is preferable to actively use a recycled material made of vehicle parts having such water repellency as the first fiber 23.

  Next, the first layer 22a constituting the inner layer 22 will be described. The first layer 22a is provided mainly for causing the fender liner 14 to exhibit noise reduction performance. That is, noise such as chipping noise, pattern noise, road noise, and the like that has passed through the surface layer 21 is absorbed by the first layer 22a. Therefore, the first layer 22a has a higher sound absorption performance than the surface layer 21 and the second layer 22b that constitute the sheet material 15 together with the first layer 22a.

  The first layer 22 a is composed of a large number of second fibers 26 and third fibers 27 and a binder 24. The 2nd fiber 26 is the main fiber of the nonwoven fabric which forms the 1st layer 22a. The third fiber 27 constitutes a nonwoven fabric together with the second fiber 26 and is included to increase the bulk of the first layer 22a. The binder 24 is for bonding a large number of second fibers 26 and third fibers 27. The first layer 22a has a network structure in which the second fibers 26 and the third fibers 27 bonded to each other by the binder 24 are entangled with each other or with each other. A large number of cells 25, which are extremely small spaces surrounded by the second fibers 26 and the third fibers 27, are formed in the first layer 22 a having a network structure. That is, the first layer 22 a is configured as a so-called “aggregate of cells 25”, and the first layer 22 a exhibits sound absorbing performance when each of the cells 25 exhibits a sound absorbing effect.

  In the first layer 22a, the second fibers 26 and the binder 24 are the same as the binder 24 mentioned in the surface layer 21. However, the fiber diameter of the second fiber 26 is larger than that of the first fiber 23. On the other hand, the binder 24 may be the same as the binder 24 used in the surface layer 21, or is not limited to using exactly the same, and may be, for example, a thermoplastic resin according to the specifications of the first layer 22a. May be changed to PET, or the fiber length and fiber diameter of the filament may be changed.

  In the present embodiment, polyethylene (PE) fibers made of staple fibers formed by cutting a recycled material are used for the second fibers 26, similarly to the first fibers 23 in the present embodiment. On the other hand, short fibers made of polyamide (PA) fibers are used for the third fibers 27. This polyamide fiber (commonly known as nylon fiber) is excellent in heat resistance, weather resistance, chemical resistance, and fatigue resistance, and contributes to the maintenance of rigidity in the first layer 22a. The polyamide fiber can also be obtained from the waste material of the airbag mounted on the vehicle 11. In other words, the airbag is produced as an end material of a base fabric used as a material at the time of manufacture, or is separated and collected at the time of a scrapped vehicle. By cutting such end material or waste material into staple fibers, the manufacturing cost of the fender liner 14 can be reduced.

  The fiber diameters of the second fiber 26 and the third fiber 27 are such that at least one of the fiber diameters of the first fiber 23 is maintained from the viewpoint of maintaining the rigidity of the fender liner 14 while exhibiting good noise reduction performance. It is thicker than the fiber diameter. In the present embodiment, the fiber diameter of the second fiber 26 is larger than the fiber diameters of the first fiber 23 and the third fiber 27. Specifically, the fiber diameters of the second fiber 26 and the third fiber 27 are preferably 10 μm or more and 50 μm or less. If the fiber diameter is less than 10 μm, the rigidity of the fender liner 14 may not be suitably maintained. On the other hand, when the fiber diameter exceeds 50 μm, the cells 25 are hardly formed in the first layer 22a, and the noise reduction performance of the fender liner 14 may be deteriorated.

The nonwoven fabric forming the first layer 22 a has a fiber density lower than that of the surface layer 21 from the viewpoint of satisfactorily exhibiting the noise reduction performance of the fender liner 14. That is, the first layer 22a is formed by reducing the fiber density, slowly packing the fibers (second fiber 26 and third fiber 27), forming a large number of cells 25, and making it soft. Sound absorption performance is improved. Specifically, the fiber density of the nonwoven fabric forming the first layer 22a is preferably 0.005 g / cm ³ or more, 0.5 g / cm from the viewpoint of maintaining appropriate rigidity while exhibiting good sound absorption performance. cm ³ or less. When the fiber density is less than 0.005 g / cm ³ , the first layer 22a becomes excessively soft, and the rigidity of the fender liner 14 may be reduced. On the other hand, when the fiber density exceeds 0.5 g / cm ³ , the fibers are clogged excessively, so that there is a possibility that the cells 25 that can satisfactorily exhibit the sound absorbing performance may not be formed.

In the nonwoven fabric forming the first layer 22a, the basis weight is made higher than that of the surface layer 21 from the viewpoint of maintaining the rigidity of the fender liner 14 while satisfactorily exhibiting noise reduction performance. Specifically, the basis weight of the first layer 22a is preferably 800 g / m ² or more and 1300 g / m ² or less, more preferably 1000 g / m ² or more and 1300 g / m ² or less. Moreover, the thickness dimension of the 1st layer 22a is 2 mm or more and 8 mm or less from a viewpoint similar to the amount of fabric weights. If the basis weight is less than 800 g / m ² or the thickness dimension is more than 8 mm, the fiber density may be excessively decreased, and the rigidity of the first layer 22a may be decreased, and moisture may enter the first layer 22a. There is also a possibility that it becomes easy to do. When the basis weight exceeds 1300 g / m ² or the thickness dimension is less than 2 mm, the fiber density of the nonwoven fabric forming the first layer 22a is excessively increased, and the cells 25 that can sufficiently exhibit noise reduction performance are provided. May not be formed.

  Next, the second layer 22b constituting the inner layer 22 will be described. The second layer 22b is provided mainly for the purpose of giving the fender liner 14 rigidity that can withstand the increase in weight due to water absorption. That is, each of the surface layer 21 and the first layer 22a has a large number of cells 25 in order to exhibit sound absorbing performance. In the fender liner 14, the water splashed by the tire 12 enters the surface layer 21 through the cells 25 and further penetrates from the surface layer 21 into the first layer 22 a, so that the weight of the surface layer 21 and the first layer 22 a is increased. There is a high possibility that the surface layer 21 and the first layer 22a will be bent and the like. Accordingly, the tensile strength of the second layer 22b is higher than that of the surface layer 21 and the second layer 22b in order to resist the shape change accompanying the increase in weight of the surface layer 21 and the first layer 22a. In consideration of the case where noise passes through the surface layer 21 and the first layer 22a, the second layer 22b is also provided with noise reduction performance in order to reduce the noise.

  The second layer 22b is formed from a nonwoven fabric obtained by a spunbond method. The spunbond method is a method of forming a web from synthetic fibers obtained by spinning a synthetic resin, and entangle or bond the synthetic fibers forming the web to obtain a nonwoven fabric. The second layer 22b of the present embodiment is composed of fourth fibers 28 and an adhesive 29 as a binder. The 4th fiber 28 is a main fiber of the nonwoven fabric which forms the 2nd layer 22b, and consists of synthetic fibers. The adhesive 29 is for bonding the fourth fibers 28 to each other. The second layer 22b has a network structure by causing the fourth fibers 28 bonded to each other by the adhesive 29 to be entangled with each other. A large number of cells 25, which are extremely small spaces surrounded by the fourth fibers 28, are formed inside the second layer 22b having a network structure. That is, the second layer 22b is configured as a so-called “aggregate of cells 25”, and each of the cells 25 exhibits a sound absorbing effect, whereby the second layer 22b exhibits noise reduction performance.

  Further, in the second layer 22b formed from the nonwoven fabric obtained by the spunbond method, a plurality of the fourth fibers 28 are bonded around the bonding point with the adhesive 29 having a large lump shape as the bonding point. . Further, these adhesion points (adhesive 29 having a lump shape) are connected to each other via the fourth fibers 28. Therefore, the non-woven fabric forming the second layer 22b has a crosslinked structure in which the fourth fibers 28 and the adhesion points are constrained to each other and are prevented from shifting in position. The non-woven fabric having a cross-linked structure has a hardness that can give a firm feeling (elasticity), and the shape is difficult to break. As a result, the second layer 22b exhibits a suitable tensile strength. When the surface layer 21 and the first layer 22a try to change in shape with an increase in weight, the second layer 22b withstands the change in shape and the fender liner 14 Keep the shape of.

  As the fourth fiber 28, a synthetic fiber obtained by a spinning method such as melt spinning, wet spinning, melt blow, flash spinning or the like, which is applicable to the spunbond method, is used. In addition, as a synthetic resin used as the material of the 4th fiber 28, as long as it is a synthetic resin applicable to a spun bond method, you may use any. In this embodiment, polyethylene (PE) fiber is used. Any adhesive 29 may be used as long as the fourth fibers 28 can be bonded, and is appropriately selected according to the synthetic resin used for the material of the fourth fibers 28. In this embodiment, an acrylic emulsion-type adhesive capable of adhering polyethylene is used.

The non-woven fabric forming the second layer 22b has the same or lower fiber density than the surface layer 21 from the viewpoint of suitably maintaining the noise reduction performance of the fender liner 14 while having good tensile strength. Yes. That is, the second layer 22b is packed with fibers (fourth fibers 28) to such an extent that a crosslinked structure can be formed, and a number of cells 25 are formed between the fibers, thereby providing the noise reduction performance and its tensile strength. Has been increased. Specifically, the fiber density of the nonwoven fabric forming the second layer 22b is preferably 0.01 g / cm ³ or more and 0.95 g / from the viewpoint of maintaining noise reduction performance while having good tensile strength. cm ³ or less. When the fiber density is less than 0.01 g / cm ³ , the crosslinked structure cannot be suitably formed, and the tensile strength may not be exhibited satisfactorily. On the other hand, when the fiber density exceeds 0.95 g / cm ³ , the fibers are clogged excessively, and there is a possibility that the cells 25 that can maintain the noise reduction performance may not be formed.

In the nonwoven fabric forming the second layer 22b, the weight per unit area is preferably 50 g / m ² or more and 500 g / m from the viewpoint of suitably maintaining the noise reduction performance of the fender liner 14 while having good tensile strength. ² or less, more preferably 50 g / m ² or more and 300 g / m ² or less. The thickness dimension of the second layer 22b is preferably 0.3 mm or more and less than 8 mm, more preferably 0.5 mm or more and 5 mm or less, more preferably 0.5 mm, from the same viewpoint as the basis weight. Above, it is 2 mm or less. Basis weight less than 50 g / m ^2, or if the thickness is more than 8 mm, the fiber density is excessively decreased, the second layer 22b may become impossible to exhibit good tensile strength. On the other hand, when the basis weight exceeds 500 g / m ² or the thickness dimension is less than 0.3 mm, the fiber density of the nonwoven fabric forming the second layer 22b is excessively increased, and the cell can maintain the noise reduction performance. 25 may not be formed.

Next, the production of the sheet material 15 in the fender liner 14 will be described.
In the manufacture of the sheet material 15, fibers and binders are opened and deposited, and a web is formed for each layer in order to obtain nonwoven fabrics that form the surface layer 21, the first layer 22 a, and the second layer 22 b. Thereafter, these webs are superposed and needle punched. Then, the webs are integrated by interlacing the fibers between the webs. Then, the integrated web is subjected to heat treatment while being pressed by a press molding machine, whereby the fibers are bonded to each other by the binder, and the sheet material 15 serving as the original fabric of the fender liner 14 is formed. When the fender liner 14 is formed from the sheet material 15, the sheet material 15 is further pressed and shaped into a predetermined shape while being heated in a mold of a press molding machine. Therefore, when the fender liner 14 is formed from the sheet material 15, the surface layer 21, the first layer 22a, and the second layer 22b are further compressed.

  The sheet material 15 that is the original fabric of the fender liner 14 is in a state in which the surface layer 21, the first layer 22a, and the second layer 22b are laminated. The fender liner 14 has a desired tensile strength in the state of the sheet material 15 serving as a raw fabric. That is, the fender liner 14 is formed by heating and pressing the sheet material 15 into a predetermined shape, and the tensile strength thereof is not lower than the tensile strength in the state of the sheet material 15 and is the same or Get higher. Therefore, the fender liner 14 only needs to satisfy the desired tensile strength in the state of the sheet material 15. The desired tensile strength indicates a tensile strength that can withstand the increase in weight when the fender liner 14 absorbs water and increases in weight. Specifically, the tensile strength in the state of the sheet material 15 is preferably 1500 N or more in the vertical direction and 1700 N or more in the horizontal direction. When the tensile strength is less than 1500 N in the vertical direction and less than 1700 N in the horizontal direction, the shape change of the fender liner 14 may not be suppressed when the weight increases due to water absorption. In addition, let this tensile strength be the value measured by the nonwoven fabric joint test method prescribed | regulated to JISL1085: 1998.

Next, the operation of the fender liner 14 will be described.
Now, the fender liner 14 reduces noise by providing the soundproof performance of the surface layer 21, the first layer 22a, and the second layer 22b against noise. That is, when so-called “noise” in the vehicle 11 is taken into consideration, there are noise that is propagated through air, such as pattern noise, and noise that is propagated through solid bodies, such as road noise, for example. is there. Of these noises, air-borne noise can be reduced by the “sound absorption effect”. That is, when noise is about to pass through the cells 25 of the surface layer 21, the first layer 22a, and the second layer 22b, the fender liner 14 causes the air to mediate because each cell 25 exerts a sound absorbing effect. Noise is absorbed and the noise is reduced. On the other hand, noise transmitted through a solid can be reduced by the “vibration control effect”. That is, the fender liner 14 has both strength and flexibility because the fiber density is different in each of the surface layer 21, the first layer 22a, and the second layer 22b. For this reason, the fender liner 14 is less likely to be deformed against vibration caused by noise, and further exhibits a vibration damping effect of flexibly absorbing vibration, thereby reducing noise propagated through solids. .

  Further, in the fender liner 14, the noise is reduced by the air layer 19 even when the noise passes through the surface layer 21, the first layer 22 a, and the second layer 22 b. That is, since the air layer 19 is composed only of air, it exhibits both a sound absorption effect and a vibration damping effect. That is, when the noise that has passed through the surface layer 21, the first layer 22a, and the second layer 22b is propagated through air, the air layer 19 absorbs the sound by shifting the phase of the noise that is propagated through the medium. Demonstrate the effect. The noise whose phase is shifted in this way is a sound that is difficult to be recognized as so-called “noise”. The air layer 19 suppresses contact between the surface layer 21, the first layer 22a, and the second layer 22b and the tire house 13, and suppresses the vibration of each solid layer from being transmitted to the tire house 13. In this way, the damping effect is demonstrated. As a result, the air layer 19 of the fender liner 14 reduces air and solid-borne noise.

  In the fender liner 14, by changing the volume of the air layer 19, the frequency band that exhibits the sound absorption effect is appropriately adjusted according to the frequency band of noise to be reduced. When the volume of the air layer 19 is changed in this way, the change is made by changing the height of the bead 18, that is, the thickness of the air layer 19. Specifically, the thickness of the air layer 19 is preferably 5 mm or more and 40 mm or less from the viewpoint of suitably housing the fender liner 14 inside the tire house 13 while suitably improving noise reduction performance. When the thickness of the air layer 19 is less than 5 mm, the air layer 19 cannot exhibit a sufficient sound absorbing effect, and may not be able to sufficiently contribute to the improvement of noise reduction performance. On the other hand, when the thickness of the air layer 19 exceeds 40 mm, it is possible to exhibit a sufficient sound absorption effect, but the space required for mounting the fender liner 14 increases, and the fender liner 14 is accommodated in the tire house 13. You may not be able to do it.

  In addition, the fender liner 14 reduces not only noise that enters the vehicle interior of the vehicle 11 but also noise that tends to leak out of the vehicle 11. That is, the fender liner 14 has the above-described sound absorption effect and vibration suppression effect even for noises such as engine noise and motor noise of the vehicle 11 that are about to leak from the inside of the vehicle 11 to the outside of the vehicle 11. Demonstrate. Accordingly, noise that tends to leak out of the vehicle 11 is reduced by the fender liner 14, and the vehicle 11 including the fender liner 14 can contribute to environmental consideration at a high level.

  On the other hand, when the vehicle 11 travels, the pebbles and the like that the tire 12 jumps up collide with the fender liner 14 and try to generate chipping noise. At this time, the fender liner 14 received the force due to the collision by the surface layer 21 given rigidity (hardness) by increasing the fiber density, and further provided the flexibility by making the fiber density lower than the surface layer 21. The first layer 22a absorbs the force caused by the collision. As a result, generation of chipping noise is suppressed. Further, pebbles and the like that have collided with the fender liner 14 are entangled with the fibers on the surface of the surface layer 21 and try to adhere. On the other hand, the smoothness of the surface layer 21 is improved by increasing the fiber density and closely packing the fibers (first fibers 23). Therefore, the fuzz of fibers on the surface of the surface layer 21 is reduced, and sticking of pebbles and the like is suppressed, so that the fender liner 14 can suitably withstand the fouling.

  Further, when the vehicle 11 is traveling, moisture such as rain water and snow may adhere to the fender liner 14 and the moisture may be absorbed. In this case, a part of the water adhering to the surface of the surface layer 21 is made water-repellent by imparting water repellency to the surface layer 21. Therefore, the water absorption in the surface layer 21 is suppressed. On the other hand, the water absorbed from the surface layer 21 without being water-repellent increases the weight of the fender liner 14 and tends to be deformed by bending the fender liner 14. At this time, the second layer 22b resists the force to deform the fender liner 14 and suppresses the deformation. Further, when the surface layer 21 and the first layer 22a are compared, the surface layer 21 has higher fiber density than the first layer 22a, and thus has high rigidity and is difficult to deform. For this reason, the second layer 22b and the surface layer 21 having rigidity sandwich and support the soft first layer 22a, whereby deformation due to weight change is suitably suppressed. In addition, since the second layer 22b is formed of a nonwoven fabric obtained by the spunbond method, the cell 25 is smaller than the cell 25 formed in the surface layer 21 and the first layer 22a. Therefore, when moisture enters the air layer 19, water absorption from the second layer 22b is suppressed.

The effects exhibited by the first embodiment will be described below.
(1) In the fender liner 14, each of the surface layer 21, the first layer 22 a, and the second layer 22 b is formed from a nonwoven fabric, thereby being configured as an assembly of cells 25. Therefore, the fender liner 14 can exhibit noise reduction performance when the cell 25 exhibits the sound absorbing effect. Further, the inner layer 22 composed of the first layer 22 a and the second layer 22 b has a higher tensile strength than the surface layer 21. For this reason, when the fender liner 14 increases the weight due to moisture absorption and attempts to change the shape, the inner layer 22 resists the force to change the shape and suppresses the change in shape. For this reason, while making the noise reduction performance suitable by the sound absorbing effect of the cells 25 of each layer, the tensile strength of the inner layer 22 is increased more than the surface layer 21, so that the fender liner 14 has a rigidity that can withstand the increase in weight due to water absorption. Can be granted.

The fiber density of the (2) the surface layer 21, 0.05 g / cm ³ or more, by which a 0.95 g / cm ³ or less, to impart durability that can sufficiently resistant to chipping in the fender liner 14 it can.

  (3) In the surface layer 21, by setting the fiber diameter of the first fibers 23 to 5 μm or more and 20 μm or less, it is possible to form the cells 25 that are sufficient to exert a sufficient sound absorption effect, and to increase the rigidity of the surface layer 21. It can be made suitable.

  (4) An air layer 19 is provided between the second layer 22 b and the outer surface 13 a of the tire house 13. Providing this air layer 19 shifts the phase of the noise and makes it difficult for the vibration of the fender liner 14 to be transmitted to the body of the vehicle 11, so that the noise reduction performance of the fender liner 14 can be suitably improved. .

  (5) By forming the second layer 22b with a nonwoven fabric obtained by the spunbond method, the second fiber 22 and the adhesion point (adhesive 29) are mutually restrained in the second layer 22b, and the mutual positions Deviation can be suppressed. For this reason, the tensile strength of the inner layer 22 can be suitably increased by the second layer 22b. Further, by providing the inner layer 22 with a multi-layer structure of the first layer 22a and the second layer 22b, the first layer 22a is provided with good sound absorption performance and the second layer 22b is provided with good tensile strength. Can do.

  (6) By laminating the surface layer 21, the first layer 22a, and the second layer 22b in this order, the soft first layer 22a can be sandwiched and supported by the rigid surface layer 21 and the second layer 22b. That is, each of the surface layer 21, the first layer 22a, and the second layer 22b constitutes a so-called exoskeleton structure, and the surface layer 21 and the second layer 22b exhibit a so-called beam function, so that the rigidity of the fender liner 14 is increased. It can be made suitable.

  (7) In the state of the sheet material 15 in which the surface layer 21, the first layer 22a, and the second layer 22b are laminated, the tensile strength is set to 1500 N or more in the vertical direction and 1700 N or more in the horizontal direction. It can withstand the increase well.

  (8) Since the non-woven fabric forming the second layer 22b has the same or lower fiber density than the non-woven fabric forming the surface layer 21, sufficient sound absorption between the fourth fibers 28 in the second layer 22b. The cell 25 having a size sufficient to exert the effect can be formed.

(9) The non-woven fabric forming the second layer 22b preferably maintains the noise reduction performance in the second layer 22b by setting the fiber density to 0.01 g / cm ³ or more and 0.95 g / cm ³ or less. However, the tensile strength can be improved.

  (10) Since the nonwoven fabric forming the first layer 22a has a fiber density lower than that of the nonwoven fabric forming the surface layer 21, the first layer 22a has good sound absorption while suitably maintaining its durability. Performance can be demonstrated.

(11) non-woven fabric forming the first layer 22a is a fiber density 0.005 g / cm ³ or more, by which the 0.5 g / cm ³ or less, while maintaining the durability of the first layer 22a preferably, The first layer 22a can mainly exhibit sound absorbing performance.

  (12) In the first layer 22a, the second fiber 26 has a fiber diameter larger than that of the first fiber 23. Therefore, a large number of cells 25 are formed to such an extent that a good sound absorbing effect can be exhibited. However, the durability performance of the first layer 22a can be suitably maintained.

  (13) In the first layer 22a, the second fiber 26 and the third fiber 27 form a large number of cells 25 capable of exhibiting a good sound absorption effect when the fiber diameter is 10 μm or more and 50 μm or less. However, the durability performance of the first layer 22a can be maintained satisfactorily.

(14) Chipping frequently occurs in the tire house 13. Further, the tire house 13 is a place where noise such as chipping noise, pattern noise, road noise and the like enters the vehicle interior. By providing the fender liner 14 attached to the tire house 13 with the surface layer 21, the first layer 22a, and the second layer 22b as described above, the fender liner 14 preferably has noise reduction performance. While exhibiting, it also exhibits suitable durability performance. Therefore, such a fender liner 14 can improve the quiet performance in the passenger compartment in addition to the original purpose of protecting the body of the vehicle 11 from chipping. Furthermore, the inside of the tire house 13 is also a place where moisture easily adheres. Since the fender liner 14 includes the surface layer 21, the first layer 22a, and the second layer 22b and has improved tensile strength, it can suitably withstand a shape change caused by water absorption.
(Second Embodiment)
Hereinafter, a second embodiment of the present invention will be described. The second embodiment will be described with a focus on differences from the first embodiment.

  FIG. 5 is a schematic diagram showing a cross-sectional structure of the fender liner 14 in the second embodiment. The fender liner 14 has a laminated structure in which a layer made of a sheet material 15 and the air layer 19 are laminated. Further, the sheet material 15 has a laminated structure in which a plurality of layers are laminated. In the present embodiment, the sheet material 15 has a laminated structure in which two layers are laminated. That is, when the fender liner 14 is mounted on the outer surface 13 a of the tire house 13, the sheet material 15 includes a surface layer 21 that constitutes the outermost layer of the fender liner 14, and the surface layer 21 and the outer surface 13 a of the tire house 13. And an inner layer 22 disposed therebetween. The inner layer 22 has a single layer structure. Each of the surface layer 21 and the inner layer 22 is formed using a nonwoven fabric as a material. The fender liner 14 is formed by laminating three layers: a surface layer 21 and an inner layer 22 that are layers made of the sheet material 15, and an air layer 19 disposed between the inner layer 22 and the outer surface 13 a of the tire house 13. A laminated structure is formed.

Next, each layer constituting the fender liner 14 will be described in detail.
First, the surface layer 21 constituting the outermost layer of the fender liner 14 will be described. The surface layer 21 has the same configuration as that of the first embodiment except for the binder 24 to be used. That is, in the surface layer 21, the 1st fiber 23 and its fiber diameter, the fiber density of the nonwoven fabric which forms the surface layer 21, a fabric weight, and the thickness dimension of the surface layer 21 are the same as 1st Embodiment. On the other hand, the inner layer 22 has the same configuration as the first layer 22a of the first embodiment except for the binder 24 to be used. That is, the nonwoven fabric forming the inner layer 22 is configured as a so-called “aggregate of cells 25” by the second fibers 26, the third fibers 27, and the binder 24. In the inner layer 22, the second fiber 26 and the third fiber 27 and the respective fiber diameters, the fiber density of the nonwoven fabric forming the inner layer 22, the basis weight, and the thickness dimension of the inner layer 22 are the same as those in the first layer 22a of the first embodiment. Same as each. Therefore, in the inner layer 22, at least one of the second fibers 26 and the third fibers 27 is thicker than the first fibers 23, and the fiber density and basis weight are lower than those of the surface layer 21.

  In the surface layer 21 and the inner layer 22, a composite fiber obtained by combining and spinning at least two types of thermoplastic resins having different melting points is used for the binder 24. In this composite fiber, a thermoplastic resin having a melting point lower than that of the first fiber 23 is used as at least one of the thermoplastic resins. As such a thermoplastic resin, polyolefin fibers, polyester fibers such as polyethylene terephthalate (PET), and polystyrene fibers are preferably used.

  Moreover, as a composite fiber, a core-sheath type or a side-by-side type is used. The core-sheath type composite fiber is a fiber composed of a core part that is the center and a sheath part that covers the surface of the core part, and is used for the sheath part rather than the thermoplastic resin used for the core part. The melting point of the thermoplastic resin is lowered. The core-sheath type composite fiber bonds the fibers through the core part by leaving the core part and melting only the sheath part. On the other hand, a side-by-side type composite fiber is a fiber configured such that a pair of fibers are fused to each other and extend in parallel, and the thermoplastic resin used for the other of the pair of fibers is used instead of one. The melting point is low. Then, the side-by-side type composite fiber leaves one fiber, and only the other fiber is melted, thereby bonding the fibers through one fiber.

  In the nonwoven fabric using the binder 24 made of the composite fiber as described above, a large number of fibers and the binder 24 are bonded around the bonding point. In addition, there are innumerable adhesion points in the nonwoven fabric, and these adhesion points are connected to each other through the binder 24 and the fibers. Therefore, the nonwoven fabric using the binder 24 composed of the composite fiber constitutes a network structure composed of the binder 24 and the fiber while constituting a crosslinked structure composed of the binder 24 and the fiber. For this reason, the nonwoven fabric made into the bridge | crosslinking structure and the network structure has the hardness of the grade which can provide a feeling of tension (tension feeling), and a shape becomes difficult to collapse.

  In this embodiment, a core-sheath type composite fiber is used. In this way, when a core-sheath type fiber is used as the composite fiber, as shown in the enlarged view surrounded by a two-dot chain line in FIG. 5, the remaining core part is a cell between the fibers constituting the nonwoven fabric. 25 is formed. For this reason, since the network structure which consists of a binder 24 and a fiber becomes dense and the hardness (rigidity) accompanied by a feeling of tension (tensile feeling) increases, it is possible to suitably suppress the deformation of the shape. In the core-sheath type composite fiber, the fibers constituting the core portion have a lower melting point than the fibers forming the nonwoven fabric (the first fiber 23 in the surface layer 21 and the second fiber 26 and the third fiber 27 in the inner layer 22). It does not have to be, but rather has a high melting point. Therefore, in this embodiment, in the core-sheath type composite fiber, the core part is made of PET and the sheath part is made of modified polyester.

  In the binder 24 composed of the core-sheath type composite fiber, the thermoplastic resin used for the sheath part has a melting point of a thermoplastic resin used for the core part or a fiber forming a nonwoven fabric (in the surface layer 21, the first fiber 23, The inner layer 22 is preferably 20 ° C. or more lower than the melting points of the second fibers 26 and the third fibers 27). When the difference from the melting point is less than 20 ° C., it becomes difficult to melt only the sheath, and there is a possibility that the cell 25 sufficient to exhibit the sound absorbing effect cannot be formed.

  Specifically, the melting point of the thermoplastic resin used for the sheath is preferably 80 to 170 ° C, more preferably 100 to 170 ° C. When the melting point is less than 80 ° C., the sheath portion that bonds the fibers again softens due to heat applied from the body of the vehicle 11 (for example, engine heat), and the fender liner 14 may be deformed. On the other hand, when the melting point exceeds 170 ° C., it becomes difficult to form the fender liner 14 and the workability may be deteriorated.

  In the binder 24 made of the core-sheath type composite fiber, the fiber diameter is preferably 10 μm or more and 50 μm or less from the viewpoint of suitably maintaining the noise reduction performance while improving the rigidity of the fender liner 14. When the fiber diameter is less than 10 μm, the durability of the fender liner 14 may be deteriorated due to the core portion being cut or the sheath portion being unable to sufficiently bond the fibers together. On the other hand, when the fiber diameter exceeds 50 μm, the binder 24 may block the cell 25 and the noise reduction performance may be deteriorated.

Next, the production of the sheet material 15 in the fender liner 14 will be described.
In the manufacture of the sheet material 15, fibers and binders are opened and deposited so as to obtain nonwoven fabrics that form the surface layer 21 and the inner layer 22, and a web is formed for each layer. Thereafter, these webs are superposed and needle punched. Then, the webs are integrated by interlacing the fibers between the webs. Then, the integrated web is subjected to heat treatment while being pressed by a press molding machine, whereby the fibers are bonded to each other by the binder, and the sheet material 15 serving as the original fabric of the fender liner 14 is formed. When the fender liner 14 is formed from the sheet material 15, the sheet material 15 is further pressed and shaped into a predetermined shape while being heated in a mold of a press molding machine. Therefore, when the fender liner 14 is formed from the sheet material 15, the surface layer 21 and the inner layer 22 are further compressed.

  The sheet material 15 that is the original fabric of the fender liner 14 is in a state in which the surface layer 21 and the inner layer 22 are laminated. The fender liner 14 is in the state of a sheet material 15 as a raw fabric, and its tensile strength is preferably 1400 N or more in the vertical direction and 1800 N or more in the horizontal direction. When the tensile strength is less than 1400 N in the vertical direction and less than 1800 N in the horizontal direction, there is a possibility that the shape change of the fender liner 14 cannot be suppressed when the weight increases due to water absorption. As described above, the fender liner 14 is formed by heating and pressing the sheet material 15 into a predetermined shape, and its tensile strength is lower than the tensile strength in the state of the sheet material 15. It will never be the same or higher.

Next, the operation of the fender liner 14 will be described.
Now, the fender liner 14 reduces the noise propagated through the air and the solid as a medium by the surface layer 21 and the inner layer 22 exhibiting soundproof performance against the noise. Further, even when noise passes through the surface layer 21 and the inner layer 22, the noise is reduced by the air layer 19. In addition, the fender liner 14 reduces not only noise that enters the vehicle interior of the vehicle 11 but also noise that tends to leak out of the vehicle 11. On the other hand, when the vehicle 11 is traveling, the pebbles and the like that the tire 12 has jumped up are received by the surface layer 21 due to the collision, and the fiber density is made lower than that of the surface layer 21 to provide flexibility. Thus, the force due to the collision is absorbed. As a result, generation of chipping noise is suppressed.

  Further, when water is absorbed by the fender liner 14 during traveling of the vehicle 11, a part of the water adhering to the surface of the surface layer 21 is water repellent. Therefore, the water absorption in the surface layer 21 is suppressed. On the other hand, the water absorbed from the surface layer 21 without being water-repellent increases the weight of the fender liner 14 and tends to be deformed by bending the fender liner 14. At this time, the inner layer 22 resists the force to deform the fender liner 14 and suppresses the deformation. In addition, in the inner layer 22, a core-sheath type composite fiber is used for the binder 24, and dense cells 25 are formed in the inner layer 22. Therefore, when moisture enters the air layer 19, it becomes difficult for the moisture to be taken into the cells 25 of the inner layer 22, and water absorption from the inner layer 22 is suppressed.

The effects exhibited by the second embodiment will be described below. In addition, 2nd Embodiment has an effect similar to the effect as described in said (1)-(3).
(15) An air layer 19 is provided between the inner layer 22 and the outer surface 13 a of the tire house 13. Providing this air layer 19 shifts the phase of the noise and makes it difficult for the vibration of the fender liner 14 to be transmitted to the body of the vehicle 11, so that the noise reduction performance of the fender liner 14 can be suitably improved. .

  (16) In the inner layer 22, the second fiber 26 and the third fiber 27 are bonded with the binder 24 made of the core-sheath type composite fiber, thereby increasing the number of bonding points for bonding the fibers to each other. Is favorably restrained, and positional deviation between fibers can be satisfactorily suppressed. For this reason, the tensile strength of the fender liner 14 can be suitably increased by the inner layer 22.

  (17) In the state of the sheet material 15 in which the surface layer 21 and the inner layer 22 are laminated, the fender liner 14 can withstand a weight increase due to water absorption by having a tensile strength of 1400 N or more in the vertical direction and 1800 N or more in the horizontal direction. It can be.

  (18) Since the nonwoven fabric forming the inner layer 22 has a fiber density lower than that of the nonwoven fabric forming the surface layer 21, the inner layer 22 exhibits good sound absorption performance while suitably maintaining its durability performance. be able to.

(19) non-woven fabric forming the inner layer 22, the fiber density 0.005 g / cm ³ or more, by which the 0.5 g / cm ³ or less, while maintaining the durability of the inner layer 22 suitably, the inner layer 22 The sound absorbing performance can be exhibited mainly.

  (20) In the inner layer 22, the second fiber 26 has a larger fiber diameter than the first fiber 23, so that a large number of cells 25 are formed so that a good sound absorption effect can be exhibited. The durability performance of the inner layer 22 can be suitably maintained.

  (21) In the inner layer 22, the second fibers 26 and the third fibers 27 form a large number of cells 25 capable of exhibiting a good sound absorption effect by setting the fiber diameter to 10 μm or more and 50 μm or less. The durability performance of the inner layer 22 can be maintained satisfactorily.

(22) Chipping frequently occurs in the tire house 13. Further, the tire house 13 is a place where noise such as chipping noise, pattern noise, road noise and the like enters the vehicle interior. By providing the fender liner 14 attached to such a tire house 13 with the surface layer 21 and the inner layer 22 as described above, the fender liner 14 has a preferable durability while exhibiting noise reduction performance. Demonstrate performance. Therefore, such a fender liner 14 can improve the quiet performance in the passenger compartment in addition to the original purpose of protecting the body of the vehicle 11 from chipping. Furthermore, the inside of the tire house 13 is also a place where moisture easily adheres. Since the fender liner 14 includes the surface layer 21 and the inner layer 22 and has improved tensile strength, the fender liner 14 can suitably withstand a shape change caused by water absorption.
(Third embodiment)
Hereinafter, a third embodiment of the present invention will be described. The third embodiment will be described with a focus on differences from the first embodiment.

  FIG. 6 is a schematic diagram showing a cross-sectional structure of the fender liner 14 in the third embodiment. The fender liner 14 has a laminated structure in which a layer made of a sheet material 15 and the air layer 19 are laminated. Further, the sheet material 15 has a laminated structure in which a plurality of layers are laminated. In the present embodiment, the sheet material 15 has a laminated structure in which three layers are laminated. That is, when the fender liner 14 is mounted on the outer surface 13 a of the tire house 13, the sheet material 15 includes a surface layer 21 that constitutes the outermost layer of the fender liner 14, and the surface layer 21 and the outer surface 13 a of the tire house 13. And an inner layer 22 disposed therebetween. Further, the inner layer 22 has a first layer 22 a disposed on the surface layer 21 side and a second layer 22 b disposed on the outer surface 13 a side of the tire house 13. Each of the surface layer 21, the first layer 22a, and the second layer 22b is formed using a nonwoven fabric as a material. The fender liner 14 is a surface layer 21, which is a layer made of the sheet material 15, a first layer 22 a and a second layer 22 b, and air disposed between the second layer 22 b and the outer surface 13 a of the tire house 13. The layer 19 has a laminated structure in which four layers are laminated.

Next, each layer constituting the fender liner 14 will be described in detail.
First, the surface layer 21 constituting the outermost layer of the fender liner 14 will be described. The surface layer 21 has the same configuration as that of the first embodiment. That is, in the surface layer 21, the 1st fiber 23 and its fiber diameter, the fiber density of the nonwoven fabric which forms the surface layer 21, the fabric weight, and the thickness dimension of the surface layer 21 are the same as 1st Embodiment.

  On the other hand, the first layer 22a of the inner layer 22 has the same configuration as the first layer 22a of the first embodiment. That is, the non-woven fabric forming the first layer 22 a is configured as a so-called “cell 25 aggregate” by the second fibers 26, the third fibers 27, and the binder 24. In the first layer 22a, the second fiber 26 and the third fiber 27 and the respective fiber diameters, the fiber density of the nonwoven fabric forming the first layer 22a, the basis weight, and the thickness dimension of the first layer 22a are the first embodiment. The same as in the first layer 22a. Accordingly, in the first layer 22 a, at least one of the second fibers 26 and the third fibers 27 is thicker than the first fibers 23, and the fiber density and basis weight are lower than those of the surface layer 21.

  Next, the second layer 22b constituting the inner layer 22 will be described. The second layer 22b is provided mainly for the purpose of giving the fender liner 14 rigidity that can withstand the increase in weight due to water absorption. Therefore, the tensile strength of the second layer 22b is higher than that of the surface layer 21 and the second layer 22b in order to resist the shape change accompanying the weight increase of the surface layer 21 and the first layer 22a. In consideration of the case where noise passes through the surface layer 21 and the first layer 22a, the second layer 22b is also provided with noise reduction performance in order to reduce the noise.

  The second layer 22 b is composed of low elongation fibers 30 and a binder 31. The low elongation fiber 30 is a main fiber of a nonwoven fabric forming the second layer 22b, and is made of a synthetic fiber. The low elongation fiber 30 is preferably a material having an elongation of less than 20% and a tensile strength of 6 g / d to 10 g / d. In the present embodiment, a PET fiber for tire cord that has been subjected to rebuffing is used as the low elongation fiber 30. The tire cord PET fiber has higher rigidity than other PET fibers.

  The binder 31 is for bonding the low elongation fibers 30 to each other. The second layer 22b has a network structure by being in a state where the low elongation fibers 30 adhered to each other by the binder 31 are entangled with each other. A large number of cells 25, which are extremely small spaces surrounded by the low elongation fibers 30, are formed inside the second layer 22b having a network structure. That is, the second layer 22b is configured as a so-called “aggregate of cells 25”, and each of the cells 25 exhibits a sound absorbing effect, whereby the second layer 22b exhibits noise reduction performance. In this embodiment, the fiber density and the basis weight of the nonwoven fabric forming the second layer 22b are set to the same level as the nonwoven fabric forming the second layer 22b in the first embodiment.

  In this embodiment, by using the low elongation fiber 30, it contributes to the maintenance of rigidity in the second layer 22b, and as a result, the second layer 22b will exhibit a suitable tensile strength, When the surface layer 21 and the first layer 22a are to change their shape as the weight increases, the shape change of the fender liner 14 is maintained withstanding the shape change. Moreover, the PET fiber for tire cord can be obtained from the waste material of the tire mounted on the vehicle 11. In other words, the tire is produced with scraps of the base fabric used as a material at the time of manufacture, or is separated and collected at the time of scrap. The cutting cost of the fender liner 14 can be reduced by cutting the end material or the waste material and using the cut material after finishing the surface.

Next, the production of the sheet material 15 in the fender liner 14 will be described.
In the manufacture of the sheet material 15, fibers and binders are opened and deposited, and a web is formed for each layer in order to obtain nonwoven fabrics that form the surface layer 21, the first layer 22 a, and the second layer 22 b. Thereafter, these webs are superposed and needle punched. Then, the webs are integrated by interlacing the fibers between the webs. Then, the integrated web is subjected to heat treatment while being pressed by a press molding machine, whereby the fibers are bonded to each other by the binder, and the sheet material 15 serving as the original fabric of the fender liner 14 is formed. When the fender liner 14 is formed from the sheet material 15, the sheet material 15 is further pressed and shaped into a predetermined shape while being heated in a mold of a press molding machine. Therefore, when the fender liner 14 is formed from the sheet material 15, the surface layer 21, the first layer 22a, and the second layer 22b are further compressed.

Next, the operation of the fender liner 14 will be described.
Now, the fender liner 14 is propagated with respect to noise, with the surface layer 21, the first layer 22 a and the second layer 22 b exhibiting soundproofing performance, and noise propagated through air and solids as mediation. Reduce noise. Further, even when noise passes through the surface layer 21, the first layer 22a, and the second layer 22b, the noise is reduced by the air layer 19. In addition, the fender liner 14 reduces not only noise that enters the vehicle interior of the vehicle 11 but also noise that tends to leak out of the vehicle 11. On the other hand, when the vehicle 11 is traveling, the pebbles and the like that the tire 12 has jumped up are received by the surface layer 21 due to the collision, and the fiber density is made lower than that of the surface layer 21 to provide flexibility. Thus, the force due to the collision is absorbed. As a result, generation of chipping noise is suppressed.

  Further, when the vehicle 11 is traveling, moisture such as rain water and snow may adhere to the fender liner 14 and the moisture may be absorbed. In this case, a part of the water adhering to the surface of the surface layer 21 is made water-repellent by imparting water repellency to the surface layer 21. Therefore, the water absorption in the surface layer 21 is suppressed. On the other hand, the water absorbed from the surface layer 21 without being water-repellent increases the weight of the fender liner 14 and tends to be deformed by bending the fender liner 14. At this time, the second layer 22b resists the force to deform the fender liner 14 and suppresses the deformation. Further, when the surface layer 21 and the first layer 22a are compared, the surface layer 21 has higher fiber density than the first layer 22a, and thus has high rigidity and is difficult to deform. For this reason, the second layer 22b and the surface layer 21 having rigidity sandwich and support the soft first layer 22a, whereby deformation due to weight change is suitably suppressed.

  The effects exhibited by the third embodiment will be described below. In addition, 3rd Embodiment has an effect similar to the effect as described in said (1)-(6) and (8)-(14).

  (23) The second layer 22b of the inner layer 22 is formed of a nonwoven fabric including low elongation fibers 30 having an elongation of less than 20% and a tensile strength of 6 g / d to 10 g / d. It was decided. Therefore, a suitable tensile strength that can resist the change in shape of the surface layer 21 can be imparted to the second layer 22 b of the inner layer 22. Further, by providing the inner layer 22 with a multi-layer structure of the first layer 22a and the second layer 22b, the first layer 22a is provided with good sound absorption performance and the second layer 22b is provided with good tensile strength. Can do.

  (24) Since the low elongation fiber 30 has higher rigidity than other PET fibers, the basis weight in the second layer 22b is reduced as compared with the case where other PET fibers are used. Is also possible. Therefore, it is possible to reduce the weight of the second layer 22b and reduce the manufacturing cost of the fender liner 14.

  (25) Since the low-stretch fiber 30 uses PET fibers for tire cords that have been processed with fur, the use of waste materials generated during the manufacture of tires can effectively reduce the manufacturing cost of the fender liner 14. Can be planned.

(Modification)
In addition, this embodiment can also be changed and embodied as follows.
The first fiber 23, the second fiber 26, and the third fiber 27 are not necessarily made of synthetic fibers such as PET fibers, PA fibers, etc., and natural fibers such as glass fibers, ceramic fibers, etc. As the fibers, cellulose fibers such as cotton and rayon, and protein fibers such as silk and wool may be used. Or you may mix at least 2 or more types among a synthetic fiber, an inorganic fiber, and a natural fiber.

  In the case where the sheet material 15 has a laminated structure in which the surface layer 21 and the inner layer 22 are laminated, the inner layer 22 may be changed to be formed of a nonwoven fabric including the low elongation fibers 30. Moreover, when the sheet material 15 consists of a single layer, you may change so that the sheet material 15 may be formed with the nonwoven fabric containing the low elongation fiber 30. FIG. Even in this case, as the low elongation fiber 30, it is preferable to use a PET fiber for a tire cord which has been subjected to a bristle process.

-The fender liner 14 may be colored in a color tone such as black, gray, or brown according to the body color of the vehicle 11 or desired.
The exterior material is not limited to the fender liner 14 and may be embodied in any material as long as it is attached to the lower part of the vehicle 11 body. For example, the exterior material may be embodied in a quarter liner, a protector fuel cover, or the like that is attached to a tire house provided in a rear fender at the rear of the vehicle 11 body. In addition, you may materialize an exterior material in the under protector attached so that the body lower surface of the vehicle 11 may be covered. Alternatively, the exterior material may be embodied as Cd spats attached in the vicinity of the front end edge of the tire house 13. Even when configured in this manner, the same effects as the effects described in (1) to (13) and (15) to (21) are obtained.

  The air layer 19 may be omitted and the fender liner 14 may be configured. When the air layer 19 is omitted, the inner layer 22 of the fender liner 14 is in contact with the outer surface 13 a of the tire house 13.

  -The binder 24 is not limited to that described in each embodiment, and may be in the form of particles, powders, or liquids as long as each fiber can be bonded and a desired tensile strength can be imparted. Moreover, you may use the binder 24 which consists of a core-sheath-type composite fiber used in 2nd Embodiment at least any one among the surface layer 21 and 1st layer 22a of 1st Embodiment. Alternatively, the binder 24 used in the first embodiment may be used in at least one of the surface layer 21 and the inner layer 22 of the second embodiment.

The third fiber 27 may be omitted, and the first layer 22a or the inner layer 22 may be formed with only the second fiber 26 and the binder 24.
The fender liner 14 is not limited to being configured only by each layer shown in each embodiment, and may be provided with other layers. For example, a layer formed of a sound insulating material such as a metal sheet or asphalt sheet may be laminated between the surface layer 21 and the first layer 22a or the inner layer 22 or on the surface of the inner layer 22 or the second layer 22b. In addition, when providing such a layer, it is preferable that this layer is set as the structure which has many holes like the cell 25. FIG.

  -The fender liner 14 which is an exterior material is not limited to the structure in which the whole has a laminated structure. You may shape | mold this fender liner 14 so that it may have a laminated structure in one part.

Further, the technical idea that can be grasped from the embodiment will be described below.
The exterior material according to any one of claims 6 to 15, wherein the nonwoven fabric forming the first layer has a higher basis weight than the nonwoven fabric forming the surface layer.

  The exterior material according to any one of claims 16 to 21, wherein the nonwoven fabric forming the inner layer has a higher basis weight than the nonwoven fabric forming the surface layer.

Schematic which shows the state which attached the fender liner of 1st Embodiment to the vehicle. The perspective view which shows the state which looked at the fender liner of 1st Embodiment from the outer side of the vehicle. The perspective view which shows the state which looked at the fender liner of 1st Embodiment from the inner side of the vehicle. The schematic diagram which shows the cross-section of a fender liner in the 4-4 instruction line of FIG. The schematic diagram which shows the cross-section of the fender liner of 2nd Embodiment. The schematic diagram which shows the cross-section of the fender liner of 3rd Embodiment.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 11 ... Vehicle, 11a ... Fender as body, 14 ... Fender liner as exterior material, 19 ... Air layer, 21 ... Surface layer, 22 ... Inner layer, 22a ... First layer, 22b ... Second layer, 23 ... Nonwoven fabric of surface layer 1st fiber that forms a layer, 24 ... a binder, 26 ... a second fiber that forms a non-woven fabric of the inner layer or the first layer, 27 ... a third fiber that forms a non-woven fabric of the inner layer or the first layer, 29 ... an adhesive as a binder 30 ... Low elongation fiber as a fiber material, 31 ... Binder.

Claims (22)

It is a shape corresponding to at least a part of the lower body part in the vehicle, and is an exterior material attached on the outer surface of the lower body part,
When attached on the outer surface of the lower part of the body, it has a surface layer arranged in the outermost layer, and an inner layer arranged between the surface layer and the lower part of the body,
The surface layer and the inner layer are each formed from a nonwoven fabric formed by molding a large number of fibers into a sheet shape,
The non-woven fabric forming the inner layer has a higher tensile strength than the non-woven fabric forming the surface layer. Nonwoven fabric, fiber density 0.05 g / cm ³ or more, the exterior material according to claim 1, characterized in that 0.95 g / cm ³ or less to form the surface layer.   The exterior material according to claim 1 or 2, wherein the nonwoven fabric forming the surface layer has a fiber diameter of 5 µm or more and 20 µm or less. It has an air layer arrange | positioned between the said inner layer and the said body lower part, The exterior material as described in any one of Claims 1-3 characterized by the above-mentioned.   The nonwoven fabric forming the inner layer includes a fiber material having an elongation of less than 20% and a tensile strength of 6 g / d or more and 10 g / d or less. The exterior material as described in any one of these. The inner layer has a multilayer structure including at least two layers of a first layer and a second layer, and each of the first layer and the second layer is formed of a nonwoven fabric,
The nonwoven fabric forming the second layer includes a fiber material having an elongation of less than 20% and a tensile strength of 6 g / d or more and 10 g / d or less. Item 5. The exterior material according to any one of Items 4 The inner layer has a multilayer structure including at least two layers of a first layer and a second layer, and each of the first layer and the second layer is formed of a nonwoven fabric,
The exterior material according to any one of claims 1 to 4, wherein a nonwoven fabric obtained by a spunbond method is used for the second layer.   As a state in which the surface layer and the first layer and the second layer of the inner layer are laminated, the tensile strength measured by the non-woven fabric test method defined in JIS L 1085: 1998 is 1500 N or more in the vertical direction. It is 1700N or more, The exterior material of Claim 7 characterized by the above-mentioned.   The said inner layer is arrange | positioned so that the said 1st layer may become the said surface layer side, and the said 2nd layer may become the outer surface side of the said body lower part, The Claim 1 characterized by the above-mentioned. The packaging material described.   The exterior material according to any one of claims 6 to 9, wherein the nonwoven fabric forming the second layer has the same or lower fiber density than the nonwoven fabric forming the surface layer. 11. The nonwoven fabric forming the second layer has a fiber density of 0.01 g / cm ³ or more and 0.95 g / cm ³ or less, according to claim 6. Exterior material.   The exterior material according to any one of claims 6 to 11, wherein the nonwoven fabric forming the first layer has a fiber density lower than that of the nonwoven fabric forming the surface layer. Nonwoven fabric forming the first layer, the fiber density of 0.005 g / cm ³ or more, according to claims 6, characterized in that it is 0.5 g / cm ³ or less in any one of claims 12 Exterior material.   The exterior material according to any one of claims 6 to 13, wherein the nonwoven fabric forming the first layer has a fiber diameter larger than that of the nonwoven fabric forming the surface layer.   The exterior material according to any one of claims 6 to 14, wherein the nonwoven fabric forming the first layer has a fiber diameter of 10 µm or more and 50 µm or less.   The nonwoven fabric forming the inner layer contains a binder for bonding fibers together, and the binder is a composite fiber obtained by combining and spinning at least two types of thermoplastic resins having different melting points. The exterior material according to any one of claims 1 to 4, wherein the exterior material is used.   The tensile strength measured by the nonwoven fabric test method defined in JIS L 1085: 1998 as a state in which the surface layer and the inner layer are laminated is 1400 N or more in the vertical direction and 1800 N or more in the horizontal direction, Item 15. A packaging material according to Item 16.   The exterior material according to claim 16 or 17, wherein the nonwoven fabric forming the inner layer has a fiber density lower than that of the nonwoven fabric forming the surface layer. Nonwoven fabric forming the inner layer, the fiber density of 0.005 g / cm ³ or more, the exterior according to claims 16, characterized in that 0.5 g / cm ³ or less in any one of claims 18 Wood.   The exterior material according to any one of claims 16 to 19, wherein the nonwoven fabric forming the inner layer has a fiber diameter larger than that of the nonwoven fabric forming the surface layer.   The exterior material according to any one of claims 16 to 20, wherein the nonwoven fabric forming the inner layer has a fiber diameter of 10 µm or more and 50 µm or less.   The fender liner for covering the outer surface of the tire house by being formed in a shape along the outer surface of the tire house in the lower part of the body. The exterior material according to claim 1.

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