JP2017171103A - Molded ceiling material for vehicle - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a molded ceiling material for a vehicle that can be molded in a desired shape even if the material needs to be formed in a complicated shape while enhancing rigidity of both side parts in a vehicle width direction and further can be prevented from becoming defective.SOLUTION: A ceiling material main body 2 comprises: an urethane layer 3; a first reinforcement layer 4 and a second reinforcement layer 5 provided both inside and outside a vehicle interior respectively of the urethane layer 3; an epidermal layer 6 provided inside the vehicle interior of the first reinforcement layer 4; and a backside layer 7 provided outside the vehicle interior of the second reinforcement layer 5, and is formed by curing an isocyanate adhesive impregnated previously in the first reinforcement layer 4 and the second reinforcement layer 5 and then sticking the layers to each other. Between the second reinforcement layer 5 and the backside layer 7 in both sides in the vehicle width direction of the ceiling material main body 2 is provided a paper material layer 8 having many through-holes 8a.SELECTED DRAWING: Figure 3

Description

  The present invention relates to a molded ceiling material for a vehicle provided on a vehicle interior side of a roof panel in a vehicle.

  Conventionally, a molded ceiling material for a vehicle having a panel shape facing the vehicle interior is disposed on the vehicle interior side of the roof panel in a vehicle such as an automobile. For example, a molded ceiling material for a vehicle disclosed in Patent Document 1 includes a ceiling material body having a substantially rectangular shape in a plan view, and an opening for an overhead console is provided at a center portion on the vehicle front side of the ceiling material body. Is formed. The ceiling material body is formed by press-molding a laminated sheet using a heated mold and curing the thermosetting adhesive impregnated in each sheet of the laminated sheet and bonding the sheets together. A base material layer made of a rigid urethane foam material, first and second reinforcing layers made of a fiber material provided on the vehicle interior side and the vehicle interior outside of the base material layer, and the vehicle compartment of the first reinforcement layer, respectively. An outer skin layer provided on the inner side and a back layer provided on the outer side of the cabin of the second reinforcing layer are provided. A paper material layer is provided between the second reinforcing layer and the back layer around the overhead console opening of the ceiling material body to increase the rigidity around the opening.

Japanese Patent Laid-Open No. 2004-66629

  By the way, the both sides of the ceiling material main body in the vehicle width direction have a curved shape that is gradually positioned downward toward the end so as to follow the shape of the both sides in the vehicle width direction of the roof panel of the vehicle. Therefore, the both sides of the ceiling material body in the vehicle width direction are formed while being stretched to the outside in the vehicle width direction when the ceiling material body is molded by the molding die, thereby reducing the thickness and reducing the rigidity. Resulting in.

  In order to avoid this, it is conceivable to reinforce the portion by providing a paper material layer as disclosed in Patent Document 1 between each layer in the both sides of the ceiling material body in the vehicle width direction.

  However, in recent years, as the design of the vehicle has become more complicated, both sides of the ceiling material body in the vehicle width direction are stretched not only to the outside in the vehicle width direction but also in multiple directions and the amount to be stretched has increased. If a paper material layer made of a material that is not easily stretched is provided on both sides of the ceiling material body in the vehicle width direction, the paper material layer may break during molding and may not be molded into a desired design.

  In addition, when a paper material layer is provided between the layers in the ceiling material body as described above, the adhesive impregnated in the reinforcing layer becomes difficult to move to the layer located on the opposite side of the paper material layer, There may be incomplete adhesion between layers, or the evaporated adhesive may remain as bubbles inside the ceiling material body and swell to affect the design of the ceiling material body, resulting in a defective product. There is.

  The present invention has been made in view of such a point, and the object of the present invention is to form a desired shape even if it is a complicated shape while increasing the rigidity of both side portions in the vehicle width direction. An object of the present invention is to provide a molded ceiling material for a vehicle that can prevent generation of defective products.

  In order to achieve the above object, the present invention is characterized in that a paper material layer is provided on both sides of the ceiling material main body in the vehicle width direction, and the paper material layer is devised.

  Specifically, the vehicle has a panel-like ceiling material body located on the vehicle interior side of the vehicle roof panel. The ceiling material body includes a base material layer made of hard foam, a vehicle interior side of the base material layer, and a vehicle. A first reinforcing layer and a second reinforcing layer made of a fiber material respectively provided on the outdoor side; a skin layer provided on the vehicle interior side of the first reinforcing layer; and provided on the vehicle outer side of the second reinforcing layer. The adhesive made of a thermosetting resin previously impregnated in the first reinforcing layer and the second reinforcing layer by pressure molding with a heated mold, and the layers are mutually bonded. In the molded ceiling material for vehicles formed by bonding, the following solutions were taken.

  That is, in the first invention, the second reinforcement is provided between the base material layer and the second reinforcing layer in both sides of the ceiling material body in the vehicle width direction, or in the vehicle width direction both sides of the ceiling material body. A paper material layer having a large number of through holes is provided between the layer and the back layer.

  According to a second aspect, in the first aspect, each of the through holes has a diameter of 0.5 to 1.5 mm, and a pitch of each of the through holes is 1 to 3 mm.

  In the first invention, when the ceiling material body is molded, if both side portions in the vehicle width direction of the ceiling material body are stretched by the molding die, a large number of through holes formed in the paper material layer are used to deform the ceiling material body. The paper material layer does not break because it deforms while following. Therefore, the ceiling material body can be formed into a desired shape while increasing the rigidity of both sides of the ceiling material body in the vehicle width direction by the paper material layer. In addition, the adhesive impregnated in the second reinforcing layer is surely moved to the base material layer side or the back surface layer side by each through hole of the paper material layer, so that the adhesion between each layer is firmly performed. In addition, the evaporated adhesive remains as bubbles inside the ceiling material body and swells, and does not affect the design of the ceiling material body.

  In the second invention, even if the shape of the ceiling material main body is complicated, a large number of through holes formed in the paper material layer are deformed while following the deformation of the ceiling material main body at the time of molding. The ceiling material body can be reliably formed into a desired shape without breaking the layers.

It is the perspective view which simplified the vehicle which concerns on Embodiment 1 of this invention. It is the top view which looked at the ceiling material main body of the molded ceiling material for vehicles which concerns on Embodiment 1 of this invention from the vehicle interior outer side. It is sectional drawing in the III-III line of FIG. It is a figure which shows the result of having evaluated the moldability of the molded ceiling material for vehicles which concerns on Embodiment 1 of this invention. It is a figure which shows the result of having evaluated the adhesiveness of the molded ceiling material for vehicles which concerns on Embodiment 1 of this invention. It is a figure which shows the result of having evaluated the rigidity of the molded ceiling material for vehicles which concerns on Embodiment 1 of this invention. FIG. 4 is a view corresponding to FIG. 3 according to Embodiment 2 of the present invention.

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. The following description of the preferred embodiment is merely exemplary in nature.
Embodiment 1 of the Invention
1 to 3 show a vehicle 10 provided with a molded ceiling material 1 for a vehicle according to Embodiment 1 of the present invention. The molded ceiling material 1 for a vehicle includes a substantially rectangular panel-shaped ceiling material body 2 located on the vehicle interior side of the roof panel 10a of the vehicle 10, and is not shown on the roof panel 10a side of the ceiling material body 2. A harness wire and a soundproof material are attached with an adhesive tape or an adhesive.

  As shown in FIG. 3, the both sides of the ceiling material body 2 in the vehicle width direction are inclined so as to gradually be positioned downward as approaching both ends in the vehicle width direction.

  Further, as shown in FIG. 2, an overhead console opening 2a having a rectangular shape in plan view is formed in the center portion of the ceiling material body 2 on the vehicle front side.

  Further, a lamp unit opening 2b having a rectangular shape in a plan view is formed in the center portion of the ceiling material body 2 in the vehicle front-rear direction.

  As shown in FIG. 3, the ceiling material body 2 includes a urethane layer 3 (base material layer) made of a rigid foamed urethane material (hard foam), and a glass fiber material provided on the vehicle interior side of the urethane layer 3. A first reinforcing layer 4 made of the above, a second reinforcing layer 5 made of a glass fiber material provided outside the casing of the urethane layer 3, and a non-woven fabric provided on the vehicle interior side of the first reinforcing layer 4. A skin layer 6 and a back layer 7 made of a non-woven fabric provided outside the passenger compartment of the second reinforcing layer 5 are provided.

  Further, a paper material layer 8 made of recycled paper is provided between the second reinforcing layer 5 and the back surface layer 7 at both sides of the ceiling material body 2 in the vehicle width direction. 2 and 3, a large number of through holes 8a are formed.

The basis weight of the paper material layer 8 is set to 50 to 300 g / m ² .

  Moreover, each said through-hole 8a is 0.5-1.5 mm in diameter, and the pitch of each through-hole 8a is set to 1-3 mm.

  The ceiling material body 2 includes a urethane layer 3, first and second reinforcing layers 4 and 5, pre-impregnated with an isocyanate adhesive, a skin layer 6, a back layer 7, and an isocyanate adhesive (thermosetting). First, a laminated sheet (not shown) on which a paper material layer 8 preliminarily impregnated with a conductive adhesive) is prepared, and the laminated sheet is pressurized with a heated mold (not shown), thereby providing a first reinforcement. The adhesive impregnated in the layer 4, the second reinforcing layer 5, and the paper material layer 8 is cured, and the layers are bonded to each other and formed into a desired shape.

  In FIG. 3, for convenience, the thickness of each layer of the ceiling material body 2 is exaggerated.

  Next, the results of evaluating the formability, adhesiveness, and rigidity of the molded ceiling material 1 for a vehicle according to Embodiment 1 of the present invention will be described.

  FIG. 4 shows the evaluation results of formability obtained by forming the ceiling material body 2 a plurality of times under each condition while changing the diameter and pitch conditions of the through holes 8a of the paper material layer 8. FIG. When the ceiling material body 2 can be molded without any problem in each condition, ○, when the ceiling material body 2 cannot be molded, △, when the ceiling material body 2 cannot be molded × It was.

  From this result, it was found that if the diameter of each through hole 8a is small and the pitch of each through hole 8a is widened, the moldability is lowered.

  FIG. 5 shows the evaluation results of the adhesiveness obtained by molding the ceiling material body 2 a plurality of times under each condition while changing the diameter and pitch conditions of each through hole 8a of the paper material layer 8. When there is no incomplete bonding in all the ceiling material bodies 2 under each condition, and when the evaporated adhesive does not remain as bubbles inside the ceiling material body, ○, bonding with some ceiling material bodies 2 Incompletely present, or when the evaporated adhesive remains as bubbles inside the ceiling material main body, Δ, there are incomplete locations in bonding in all the ceiling material main bodies 2, or The case where the evaporated adhesive remained as bubbles inside was marked as x.

  From this result, it was found that the adhesiveness decreases when the diameter of each through hole 8a is small and the pitch of each through hole 8a is widened.

  FIG. 6 shows the evaluation results of the rigidity of the ceiling material body 2 formed while changing the diameter and pitch conditions of the through holes 8a of the paper material layer 8. FIG. The case where the desired ability was possessed was indicated by ◯, and the case where the desired ability was not exhibited was indicated by ×.

  From this result, it has been found that the rigidity is greatly reduced when the diameter of each through hole 8a is large and the pitch of each through hole 8a is narrowed.

  4 to 6, the ceiling material body 2 having the paper material layer 8 in which the diameter of each through hole 8a is 0.5 to 1.5 mm and the pitch of each through hole 8a is 1 to 3 mm is preferable. It was judged.

  As mentioned above, according to Embodiment 1 of this invention, when shape | molding the ceiling material main body 2, if the vehicle width direction both sides part of the said ceiling material main body 2 is extended by a shaping | molding die, many paper material layer 8 formed in the paper material layer 8 will be described. Since the through hole 8a is deformed while following the deformation of the ceiling material body 2, the paper material layer 8 is not broken. Therefore, the ceiling material body 2 can be formed into a desired shape while increasing the rigidity of the both sides in the vehicle width direction of the ceiling material body 2 by the paper material layer 8. Further, since the adhesive impregnated in the second reinforcing layer 5 is surely moved to the back surface layer 7 side by the respective through holes 8a of the paper material layer 8, the second reinforcing layer 5 and the paper material layer 8 are used. And the paper material layer 8 and the back surface layer 7 can be firmly bonded, and the evaporated adhesive remains as bubbles inside the ceiling material body 2 and swells. The design of the main body 2 is not affected.

Further, by setting the diameter and pitch of each through hole 8a of the paper material layer 8 to optimum values, a large number of through holes formed in the paper material layer 8 even if the shape of the ceiling material body 2 is complicated. Since 8a is deformed while following the deformation of the ceiling material body 2 during molding, the ceiling material body 2 can be reliably formed into a desired shape without breaking the paper material layer 8.
<< Embodiment 2 of the Invention >>
FIG. 7 shows Embodiment 2 of the present invention. In the second embodiment, only the position of the paper material layer 8 is different from that in the first embodiment, and the others are the same as those in the first embodiment. Therefore, only the parts different from the first embodiment will be described in detail below.

  The paper material layer 8 of the second embodiment is provided between the urethane layer 3 and the second reinforcing layer 5 at both sides of the ceiling material body 2 in the vehicle width direction.

  As described above, according to the second embodiment of the present invention, even if the position of the paper material layer 8 is provided between the urethane layer 3 and the second reinforcement layer 5, the second reinforcement layer is formed by the through holes 8a of the paper material layer 8. Since the adhesive impregnated in 5 is surely moved to the urethane layer 3 side, the same effect as in the first embodiment can be obtained.

  In addition, the thickness of the urethane layer 3 of Embodiment 1, 2 of this invention is 3-10 mm.

  In the first and second embodiments of the present invention, the first and second reinforcing layers 4 and 5 are made of glass fiber material, but may be made of vegetable fiber material.

  In Embodiments 1 and 2 of the present invention, recycled paper is used for the paper material layer 8, but horse dung paper, good quality paper, hard paper, and the like can also be used. The thickness of the paper material layer 8 is preferably 0.1 to 3.0 mm.

  INDUSTRIAL APPLICABILITY The present invention is suitable for a molded ceiling material for a vehicle provided on the vehicle interior side of a roof panel in a vehicle.

1 Molded ceiling material for vehicles 2 Ceiling material body 3 Urethane layer (base material layer)
4 first reinforcing layer 5 second reinforcing layer 6 skin layer 7 back layer 8 paper material layer 8a through hole 10 vehicle 10a roof panel

Claims (2)

A roof panel body of a vehicle is provided with a panel-like ceiling material body located on the vehicle interior side, and the ceiling material body is provided on a base material layer made of a hard foam and on the vehicle interior side and the vehicle exterior side of the base material layer, respectively. A first reinforcing layer and a second reinforcing layer made of the obtained fiber material, a skin layer provided on the vehicle interior side of the first reinforcing layer, and a back surface layer provided on the vehicle exterior side of the second reinforcing layer; The adhesive is made of a thermosetting resin previously impregnated in the first reinforcing layer and the second reinforcing layer by pressure molding using a heated mold, and the layers are bonded to each other. Molded vehicle ceiling material,
Between the base material layer and the second reinforcing layer on both sides of the ceiling material body in the vehicle width direction, or between the second reinforcing layer and the back surface layer on both sides of the ceiling material body in the vehicle width direction. Is provided with a paper material layer having a large number of through-holes. The molded ceiling member for a vehicle according to claim 1,
Each said through-hole is 0.5-1.5 mm in diameter, and the pitch of each said through-hole is 1-3 mm, The molded ceiling material for vehicles characterized by the above-mentioned.

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