JP2002046545A - Vehicular molded ceiling material and its manufacturing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a vehicular molded ceiling material and its manufacturing method capable of reducing weight without impairing appearance. SOLUTION: In this vehicular molded ceiling material 10, respective members are adhered and integrated by laminating inorganic fiber layers 11 and 13 on both sides of a foam-made base material 11 and laminating surface materials 21 and 25 on glass fiber layers on both sides of the base material via or not via hot melt films 21 and 25. The base material and at least one inorganic fiber layer of the inorganic fiber layers on both sides of the base material are subjected to impregnation hardening with a binder B.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a molded ceiling material for a vehicle and a method of manufacturing the same.

[0002]

2. Description of the Related Art On a ceiling of a vehicle such as an automobile, a molded ceiling material for a vehicle is attached to the inside of a vehicle body outer plate to provide heat insulation and decorativeness. As the molded ceiling material for a vehicle, a glass fiber layer is laminated on both sides of a foam base material made of a polyurethane foam or the like, and a face material is laminated on the glass fiber layers on both sides, and each member is bonded and integrated. Molded ceiling materials are common. One of the face materials is a surface material, and the other is a back material. In this molded ceiling material, the base material is impregnated with a binder and hardened, and the rigidity of the molded ceiling material is enhanced by the hardening of the binder.

In a conventional method for manufacturing a molded ceiling material, a binder is impregnated into the base material, and the base material, a glass fiber layer, a hot melt film and a face material are heated and compressed in a laminated state to form each component material. And the binder is cured to obtain a molded ceiling material.

[0004]

However, in response to recent demands for weight reduction of vehicles, in order to reduce the weight of molded ceiling materials, it is necessary to reduce the amount of the glass fibers and binders. It has been found that stiffness is reduced, causing problems such as folding wrinkles.

[0005] Moreover, the present inventor has made intensive studies and found that
It was found that the binder impregnated in the base material leached out of the base material by compression without penetrating into the inorganic fiber layer and flowed to the outside, and did not significantly contribute to the increase in rigidity of the molded ceiling material. In particular, it has also been found that wrinkles on the surface of the molded ceiling material are likely to occur when the rigidity near the surface material is low.

The present invention has been proposed in view of the above circumstances, and provides a molded ceiling material capable of realizing a light weight without causing a defect in appearance and a method of manufacturing the same.

[0007]

According to a first aspect of the present invention, an inorganic fiber layer is laminated on both sides of a foam base material, and the inorganic fiber layers on both sides of the base material are interposed or interposed between hot melt films. In a molded ceiling material for a vehicle in which face members are laminated and each member is bonded and integrated, a binder is impregnated into the base material and at least one of the inorganic fiber layers on both sides of the base material. It is characterized by being cured.

According to a second aspect of the present invention, the surface material on one side of the substrate in the first aspect is a surface material, and the surface material on the other side is a back material, and the binder is impregnated and cured in the inorganic fiber layer on the surface material side. It is characterized by doing.

According to a third aspect of the present invention, an inorganic fiber layer is arranged on both sides of a foam base material, and a face material is arranged on the inorganic fiber layers on both sides with or without a hot melt film. In the method for manufacturing a molded ceiling material for a vehicle in which the laminate is heated and compressed to be bonded and integrated, before the heating and compression, at least one of the inorganic fiber layers of the inorganic fiber layers on both sides of the base material and the base material Is impregnated with a binder, and thereafter, the binder is cured in the base material and the inorganic fiber layer by performing the above-mentioned heating and compression, so that the respective members are bonded and integrated.

According to a fourth aspect of the present invention, the surface material on one side of the substrate in the third aspect is a surface material, and the surface material on the other side is a back material, and the inorganic fiber layer on the surface material side is impregnated with a binder. It is characterized by.

According to a fifth aspect of the present invention, the ratio of the binder impregnated weight per unit area of the base material to the binder impregnated weight per unit area of the inorganic fiber layer is 4: 1 to 8: 1. It is characterized by the following.

[0012]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail with reference to the accompanying drawings. FIG. 1 is a partial cross-sectional view of a molded ceiling material for a vehicle according to an embodiment of the present invention, FIG. 2 is a schematic view showing an example of a method of manufacturing the molded ceiling material for a vehicle, and FIG. FIG. 4 is a schematic view showing an example of a method of manufacturing a molded ceiling material for a vehicle according to the embodiment of FIG. 3.

A molded ceiling material 10 for a vehicle shown in FIG. 1 is attached to the inside of a vehicle body outer plate for heat insulation and decoration in a vehicle interior.
2, 13, hot melt film 15, 17, surface material 2
1 and the back material 25 are laminated and integrated.

The substrate 11 imparts heat insulation and sound absorbing properties to the molded ceiling material 10 and may be a known polyurethane foam having open cells. The base material 11 is impregnated and hardened with a binder B for increasing the rigidity of the base material 11 and for bonding and integrating the base material 11 with the inorganic fiber layers 12 and 13. The base material 11
Is preferably 10% or less in order to ensure thermoformability and impregnation of the binder B.

As the binder B, there is a liquid isocyanate which is inexpensive and has good adhesiveness. This liquid isocyanate is a moisture-curing type, that is, it is reactively cured by reaction with water (which may be moisture in the air) in the presence of heat and a catalyst, and functions as an adhesive by the curing. As the liquid isocyanate, a liquid isocyanate can be used without any particular limitation. For example, aromatic TDI (toluene diisocyanate), polymeric MDI (4,4'diphenylmethane diisocyanate), NDI (1,5-naphthalenediisocyanate), TODI (tolidine diisocyanate), PPDI (paraphenylene diisocyanate), XDI (xylylene diisocyanate) Isocyanate), TMX
DI (tetramethyl xylene diisocyanate) and modified products thereof. Preferably, polymeric MDI, TDI such as urethane modification, allophanate modification, burette modification, carbimide / uretonimine modification, and other modified TDI, modified MDI and the like,
The use of modified MDIs or mixtures thereof is suitable.

Of these, liquid isocyanates having a viscosity of 3 to 300 cp are excellent in permeability and applicability, etc.
More preferred. Among them, polymeric MDI has a low vapor pressure and a good affinity with glass fiber as an inorganic fiber, and is suitable in terms of reactivity, adhesion, and workability. The type of the liquid isocyanate is appropriately selected and used depending on the adhesiveness, rigidity, reactivity, workability, and the like of the laminate.

The inorganic fiber layers 12 and 13 disposed on both sides of the substrate 11 are for increasing the rigidity of the molded ceiling member 10 and may be made of carbon fiber, glass fiber, or the like. In particular, glass fibers are preferable because they are inexpensive and have high rigidity, and glass fiber chops (obtained by cutting roving glass) are layered, or glass fiber mats, glass fiber cloths, and the like are inorganic. It is suitable as the fiber layers 12 and 13. The weight of the inorganic fiber layers 12 and 13 is appropriately determined according to the rigidity and the like required for the molded ceiling material 10.

The inorganic fiber layers 12, 13 on both sides of the substrate 11
Is impregnated and cured with the binder B. Thereby, the rigidity of the molded ceiling material 10 can be further increased, and the rigidity of the molded ceiling material 10 can be increased without increasing or decreasing the amount of the base material 11 and the inorganic fiber layers 12 and 13. Thus, a lightweight molded ceiling material 10 can be obtained. In particular, as in this example, if the inorganic fiber layer 12 on the surface material 21 side is impregnated and cured with the binder B, the surface rigidity of the molded ceiling material 10 can be efficiently increased with a small amount of the binder B, and the molded ceiling material can be improved. 10
High surface fold wrinkle prevention effect.

The same binder B to be impregnated into the base material 11 and the binder B to be impregnated into the inorganic fiber layer 12 are economical in terms of raw material management and equipment, and are preferred.
The impregnated weight of the binder B per unit area of the base material 11 and the impregnated weight of the binder B per unit area of the inorganic fiber layer 12 (including the case of both inorganic fiber layers) are 4:
The ratio of 1 to 8: 1 is preferable in terms of the surface feel of the molded ceiling material 10 and the prevention of binder B leaching during compression during the production of the molded ceiling material 10 described below.

The hot melt films 15 and 17 securely adhere the front surface material 21 and the back surface material 25 to the inorganic fiber layers 12 and 13 and also prevent the ventilation of the base material 11 to prevent the molded ceiling material from being caused by the ventilation. 10 to prevent dirt,
It is made of a material that melts when heated and exhibits adhesiveness. Examples of the hot melt layers 15 and 17 include EVA (ethylene-vinyl acetate copolymer), EAA (copolymer of ethylene and acrylic acid), EMA (copolymer of ethylene and methyl acrylate), and EMA (ethylene and methyl acrylate). A thermoplastic resin having a melting point of 70 to 100 ° C., such as a copolymer of methyl methacrylate), a copolymer of EMAA (copolymer of ethylene and methacrylic acid) and polyolefin, or a polymer alloy; polypropylene, polyamide, PET (Polyethylene terephthalate) melting point 110-200 ° C
And a polymer alloy with a thermoplastic resin.

The surface material 21 is for decorating or protecting the surface of the molded ceiling material 10 and is made of non-woven fabric such as polyester non-woven fabric, woven fabric (knit surface fabric), fabric such as polyester fiber, TPO (polyolefin thermoplastic elastomer). ) Or a plastic sheet such as PVC (polyvinyl chloride) is appropriately used.

The back material 25 is for protecting the back surface of the molded ceiling material 10 and is made of a suitable sheet material such as a nonwoven fabric or a plastic sheet.

Next, an example of a method for manufacturing the molded ceiling member 10 will be described with reference to FIG. In the following example, in order to increase production efficiency, an example is shown in which each component is continuously supplied to form a laminated material, and the laminated material is cut into a predetermined dimension after being integrated, but is not limited thereto. Instead, each member cut in advance to a predetermined size may be sequentially laminated.

First, in this example, the binder B is adhered to the substrate 11. In the illustrated example, the container M is filled with the polymeric MDI (liquid isocyanate) as the binder B, and the polymeric MDI (binder B) is filled therein.
By immersing the base material 11 in the polymer MD
I is attached to both surfaces of the substrate 11. Preferably, in order to promote the reaction hardening of the polymeric MDI, after attaching the polymeric MDI to the substrate 11, a catalyst solution such as dimethylethanolamine is preferably sprayed on the substrate 11. Here, since the above-mentioned polymeric MDI is composed of one liquid, it is not necessary to adjust the viscosity of each liquid as compared with a two-part polyurethane adhesive.
Are less expensive than two-part polyurethane adhesives. Reference numerals R1 and R2 in the drawing are squeezing rolls for squeezing the base material 11 on which the binder B (polymeric MDI) is adhered and for reliably impregnating the base material 11 with the binder B and squeezing out excess binder B. It is. By adjusting the degree of squeezing and adjusting the speed at which the base material 11 passes through the binder B of the container C, the amount of the binder B impregnated can be controlled.

Subsequently, a predetermined dimension is applied to the front surface (the upper surface during the production) of the substrate 11 to which the binder B is adhered and the front surface (the upper surface during the production) of the hot melt film 17 for the back material. Inorganic fiber 12 cut into
The inorganic fiber layers 12 and 13 are formed by spraying (adhering) A and 13A and depositing them at a predetermined weight. In addition, instead of the cut inorganic fiber, a mat or cloth of the inorganic fiber may be laminated on the front surface of the base material 11 and the front surface of the hot melt film 17 for the back material.

A binder B is applied to the inorganic fiber layer 12 laminated on the front surface of the base material 11 by spraying or the like, and is adhered and impregnated. At this time, as described above, the adhesion weight (impregnation weight) of the binder B per unit area of the substrate 11 and the inorganic fiber layer 1
The adhesion amount of the binder B is controlled so that the ratio of the adhesion weight of the binder B to the unit area of 2 is 4: 1 to 8: 1.

Thereafter, as shown in the figure, the back material 25, the hot melt film 17 for the back material on which the inorganic fiber layer 13 is laminated, the base material 11 impregnated with the binder B,
The inorganic fiber layer 12, the hot-melt film 15 for the surface material, and the surface material 21 which are laminated on the substrate 11 and are impregnated with the binder B are laminated in this order, and the laminated material 10A
Is compressed using pressure rolls R3, R4.

By the compression of the pressure rolls R3 and R4, the binder B adhered and impregnated to the base material 11 and the inorganic fiber layer 12 is surely impregnated in the base material 11 and the inorganic fiber layer 12, and B exudes between the base material 11 and the inorganic fiber layers 12 and 13 on both sides. The degree of compression of the rolls R3 and R4 is determined in consideration of the material of each member.

Next, the compressed laminated material 10A is heated and compressed by a heating mold including an upper mold 35 and a lower mold 37. When the binder B is cured by the heating and compression, the adhesion of the base material 11 and the inorganic fiber layers 12 and 13, the shaping and shape fixing to the mold surface, and the increase in rigidity are performed.
At the same time, the hot melt films 15, 17 are melted, and the melted hot melt films 15, 17 are melted.
Of the hot melt films 15, 1
The inorganic fiber layers 12 and 13 adhere to the front surface member 21 and the back surface member 25 via 7, and the respective constituent members are bonded and integrated. Thereafter, the molded ceiling material 10 can be obtained by cutting to a predetermined size with a cutting tool (not shown) such as a cutter.

FIG. 3 shows a molded ceiling member 40 according to another embodiment.
It shows a part of. Compared with the molded ceiling material 10 of the above-described embodiment, the molded ceiling material 40 does not use the hot melt films 15 and 17 and the inorganic fiber layers 12 and 13 on both sides of the base material 11 are impregnated and hardened with the binder B. And the other configuration is the same. Therefore, the same members are denoted by the same reference numerals.

The hot melt films 15 and 17 used for the molded ceiling member 10 in FIG. 1 can be omitted depending on the material of the front surface member 21 and the back surface member 25. That is, in the present invention, since the inorganic fiber layers 12 and 13 are impregnated and cured with the binder B, if the surface material 21 and the back surface material 25 are directly laminated on the inorganic fiber layers 12 and 13, the inorganic fiber layer 1
The surface material 21 and the back material 25 can be adhered to the inorganic fiber layers 12 and 13 by the binder B on the surfaces of the inorganic fiber layers 12 and 13. However, when the inorganic fibers protrude from the surface material 21 and the back material 25 due to the direct contact between the surface material 21 and the back material 25 with the inorganic fiber layers 12 and 13, as in the case of the molded ceiling material 10 of the above-described embodiment. It is preferable that hot melt films 15 and 17 are interposed between them. In addition, surface material 2
It is also possible to omit the hot melt film on only one of the first side and the back material 25 side, and to impregnate and cure the binder only in the inorganic fiber layer on the omitted side.

FIG. 4 shows an example of a method of manufacturing a molded ceiling material 40 without using the hot melt film. The manufacturing method shown in FIG. 4 does not use a hot-melt film as compared with the manufacturing method shown in FIG.
The only difference is that the binder B is applied and impregnated on the inorganic fiber layer 13 on the side, and the other points are the same. Reference numeral 40A in the figure indicates a laminated material before compression and heating.

In each of the above embodiments, the method of adhering the binder B to the inorganic fiber layers 12 and 13 is not limited to the method of directly applying the binder B to the inorganic fiber layers by spraying or roll coating. It can also be performed by an indirect method in which the binder B is applied to the hot melt films 15, 17 to be laminated, the front surface material 21, the back surface material 25, and the like.

In order to confirm the effects of the product of the present invention, in Examples 1 and 2 each having the configuration of the molded ceiling member 10 shown in FIG.
The maximum bending load according to 911 and the bending gradient according to JIS K6911 were measured, and the presence or absence of wrinkles on the surface during the measurement of the maximum bending load and the bending gradient was visually determined. For comparison, the same measurement was performed on a conventional product in which the binder was not impregnated into the inorganic fiber layer. The results are as shown in Table 1.

The thickness of the molded ceiling material is 4 mm. The surface material 21 and the back surface material 25 are polyester nonwoven fabric,
48g / m²  ・ Inorganic fiber layers 12 and 13: glass fiber roving cloth
, Thickness 0.24mm, basis weight 30g / m², Fiber diameter 11
μm, made by Asahi Fiberglass, product number SP262, base material 1
1: Foamed polyurethane, INOAC Corporation
Made, part number EL-04 Binder B: Crude MDI, Nippon Polyurethane
Made, product number HM166 ・ Hot melt film 15, 17: Aichi Plastic
Made, 25 μm to 45 μm

[0036]

[Table 1]

As is clear from Table 1, Examples 1 and 2
Is lighter than conventional products, has higher rigidity, and does not have wrinkles on its surface.

[0038]

As described above, according to the molded ceiling material for a vehicle and the method of manufacturing the same according to the present invention, not only the base material but also the inorganic fiber layer is impregnated and hardened with the binder. A molded ceiling material with high rigidity can be obtained. In particular, by impregnating and curing the inorganic fiber layer on the surface material side with the binder, the surface rigidity of the molded ceiling material can be more efficiently increased. Further, by setting the binder impregnation amount per unit area of the base material and the inorganic fiber layer to 4: 1 to 8: 1, the rigidity can be more efficiently increased without impairing the lightness.

[Brief description of the drawings]

FIG. 1 is a partial sectional view of a molded ceiling material for a vehicle according to an embodiment of the present invention.

FIG. 2 is a schematic view showing an example of a method for manufacturing the molded ceiling material for a vehicle.

FIG. 3 is a partial sectional view of a molded ceiling material for a vehicle according to another embodiment.

4 is a schematic view showing an example of a method for manufacturing a molded ceiling material for a vehicle according to the embodiment of FIG.

[Explanation of symbols]

 10, 40 Molded ceiling material for vehicles 11 Base material 12, 13 Inorganic fiber layer 15, 17 Hot melt film 21 Surface material 25 Back material B Binder

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) D04H 1/42 D04H 1/42 A 1/58 1/58 // B29L 31:58 B29L 31:58 F term (reference) 3D023 BA01 BA02 BA03 BB03 BD01 BE07 BE10 BE31 4F100 AA00B AA00C AG00 AG00B AG00C AK01D AK01E AK51 AK51A AK51B AK51C AK68G AK70G AK71G AS00A AS00B AS00C AT00D AT00E AT00G BA05 BA06 BA10D BA10E BA13 CB03 DG01B DG01C DG12D DG15D DG15E DJ01A EC182 EJ08A EJ08B EJ08C EJ172 EJ422 EJ82A EJ82B EJ82C EJ821 GB33 JK01 JL03 YY00A YY00B YY00C 4F204 AA42 AD16 AD17 AD35 AG03 AG20 AH26 FA02 FB02 FB13 FB22 FF01 FF05 FG02 FG04 FN11 FW23 4L047 AA01 CA02 CB02

Claims (5)

[Claims] An inorganic fiber layer is laminated on both sides of a foam base material, and a face material is laminated on the inorganic fiber layers on both sides of the base material with or without a hot melt film, and each member is bonded. An integrated molded vehicle ceiling material, wherein a binder is impregnated and cured into the base material and at least one of the inorganic fiber layers on both sides of the base material. Ceiling material. 2. A surface material on one side of the base material and a back surface material on the other side, and a binder is impregnated and cured in the inorganic fiber layer on the surface material side. Item 4. The molded ceiling material for vehicles according to Item 1. 3. An inorganic fiber layer is disposed on both sides of a foam base material, and a face material is disposed on the inorganic fiber layers on both sides with or without a hot melt film, and the laminate is heated. And a method for manufacturing a molded ceiling material for a vehicle to be compressed and bonded and integrated, wherein the binder is impregnated into the base material and at least one of the inorganic fiber layers on both sides of the base material before the heat compression. A method of manufacturing a molded ceiling material for a vehicle, wherein the heating and compression are performed thereafter to cure the binder in the base material and the inorganic fiber layer, and to bond and integrate the respective members. 4. The method according to claim 3, wherein the face material on one side of the base material is a surface material, and the face material on the other side is a back material, and the inorganic fiber layer on the surface material side is impregnated with a binder. A method of manufacturing a molded ceiling material for a vehicle. 5. The method according to claim 3, wherein the ratio of the binder impregnated weight per unit area of the base material to the binder impregnated weight per unit area of the inorganic fiber layer is from 4: 1 to 8: 1. Of manufacturing molded ceiling materials for vehicles.