JPH052942U - Lightweight molded ceiling material - Google Patents

Abstract

(57) [Abstract] [Purpose] While reducing the weight of the ceiling material itself,
It is intended to provide a ceiling material which is excellent in rigidity and also realizes excellent deep drawing formability. [Structure] A resin cotton made of polyester fibers and a skin layer made of glass paper were integrated, impregnated in a phenol resin, and then dried to form an integrated product. On one surface of the bulky non-woven fabric, a thin resin non-woven fabric is provided with a foamed resin coating base material by spraying a polyester resin, and the other surface is provided with a polyurethane foam sound absorbing layer and the above integrated product via a hot melt adhesive. After being provided and integrated, a ceiling material was obtained by heating and pressing at 190 ° C. for 1 minute under the condition of 5 kg / cm ² .

Description

[Detailed description of the device]

[0001]

[Industrial applications]

 The present invention relates to a light-weight molded ceiling material, and more particularly to a light-weight molded ceiling material that reduces the weight of the light-weight molded ceiling material itself and can follow even severe irregularities and is also excellent in deep drawability and sound absorption. .

[0002]

[Prior Art]

 BACKGROUND ART Conventionally, for example, as a ceiling material for automobiles, a molded ceiling material has been manufactured in which felt is singly or integrated with a non-woven fabric skin material through a bonding layer and heat-pressed.

However, a molded ceiling material made of only felt is excellent in deep-drawing formability, but satisfactory performance in sound absorption and rigidity cannot be obtained, and when it is used integrally with a nonwoven fabric skin material through an adhesive layer. However, there is a drawback that the weight of the soundproofing material itself increases.

[0004]

[Problems to be solved by the device]

 The object of the present invention is to realize a further reduction in the weight of an automobile, while reducing the weight of the molded ceiling material, while also achieving excellent sound absorption and rigidity, and also achieving excellent deep drawing formability of the molded ceiling material. On the point.

[0005]

[Means for Solving the Problems]

 As a solution to this problem, the inventors of the present invention have as a result of earnest research and found that the foamed resin coating substrate 2 is used on one surface of the sound absorbing substrate 1. Therefore, the gist of the present invention is as follows. Exist.

One surface of the sound absorbing base material 1 is integrated with the foamed resin coating base material 2, and the other surface is integrated with the sound absorbing layer 4 via the adhesive layer 3, and if necessary, further resin cotton 5 and a skin layer. A lightweight molded ceiling material, characterized in that after 6 is set, the resin coated on the base material is foamed.

The sound absorbing substrate 1 may be a bulky nonwoven fabric, a thin leaf nonwoven fabric, a glass mat, a glass paper, a foam material or the like. For example, in the case of a bulky nonwoven fabric, it is a discontinuous animal, vegetable or synthetic resinous material. It mainly comprises one or more fiber materials and a binder such as a thermosetting resin. In the case of foam material, polystyrene, polypropylene, polyurethane, etc. are preferable. Also, a sound absorbing layer in which these are filled in a honeycomb plate, a roll core, a feather core, or the like can be preferably used in terms of improving rigidity.

The foamed resin coating base material 2 is a foamed material such as a glass mat, a thin nonwoven fabric, glass paper, paper or the like on one side or both sides of a phenol resin, polyester resin, urethane resin, melamine resin, paraffin resin or the like. It is formed by coating the resin with a flow coat, spray, brush or the like. It is preferable that the base material has both the shape-retaining property and the surface-reinforcing function. The foamed resin coated on the base material is foamed and strongly bonded in the cells of the sound absorbing layer or between the fibers when they are integrated with the sound absorbing layer by heating and pressing.

The adhesive layer 3 is used to integrate the sound absorbing base material and the sound absorbing layer, and a hot melt or a coating type adhesive is used. For example, hot melt is previously used between the sound absorbing base material and the sound absorbing layer.

The sound absorbing layer 4 integrated with one surface of the sound absorbing base material via an adhesive layer may be a bulky nonwoven fabric, a thin leaf nonwoven fabric, a glass mat, a glass paper, a foam material, or the like. In the case of a foam material, one or more discontinuous fiber materials of animal, vegetable or synthetic resin type and a binder such as a thermosetting resin are mainly used. Polyurethane and the like are preferred.

When the resin cotton 5 is used, resin fibers are lightly compression-molded, and examples thereof include polyester fibers, polyamide fibers, polyvinyl alcohol fibers, and polyvinyl chloride fibers.

As the skin layer 6, it is essential that the weight can be reduced as compared with the case of using the felt, and it is preferable that the skin layer 6 also has the functions of shape retention and surface reinforcement, such as glass paper, glass mat, paper and thin leaf. Nonwoven fabrics and the like can be exemplified.

The resin cotton 5 and the skin layer 6 are preferably impregnated with a thermosetting resin in advance. The thermosetting resin is a phenol resin, a polyerter resin, a urethane resin, a melamine resin, a paraffin resin or the like, and the impregnation method is preferably dipping or coating. The amount of the thermosetting resin impregnated in the resin cotton is required to ensure the adhesion to the honeycomb plate, and is preferably about 1 to 100% of the weight of the resin cotton.

As a method of integrally molding each constituent material and simultaneously foaming, for example, a foamed resin coating substrate is provided on one surface of a sound absorbing substrate, and an adhesive layer and a sound absorbing layer are provided on the other surface. When the sound absorbing base material is placed by providing the resin cotton and the skin layer, the condition of 140 to 250 ° C. for 30 seconds to 2 minutes and 1 to 200 kg / cm ² is preferable.

[0015]

【Example】

 Examples will be given below to provide a more detailed understanding of the present invention. Naturally, the idea is not limited to the following examples.

[0016]

Example 1 A resin cotton made of polyester fiber and a skin layer made of glass paper were integrated, impregnated in a phenol resin, and then dried to obtain an integrated product A. On one side of the bulky non-woven fabric, a thin resin non-woven fabric is coated with a polyester resin by spraying, and a foamed resin coating substrate is provided. A is provided and integrated. The integrated material was heated and pressed at 190 ° C. for 1 minute under the condition of 5 kg / cm ² to obtain a ceiling material 1.

[0017]

Example 2 A resin cotton made of polyvinyl chloride fiber and a skin layer made of a glass mat were integrated, impregnated in a melamine resin and then dried to obtain an integrated product B. On one surface of the glass mat, a foamed resin coating substrate obtained by coating a glass paper with urethane resin by spraying was provided, and on the other surface, the above-mentioned integrated product B was integrated through a thin-leaf nonwoven fabric. 50 seconds at such monolith 200 ° C., to obtain a 5 kg / cm heat pressure molding was Shimete ceiling material 2 with ² conditions.

[0018]

【Test method】

The weight per 1 m ^{2 of the} ceiling material 1 to the ceiling material 2 was measured, and the sound absorption coefficient was measured by the reverberation room method.

[0019]

【result】

The weight of the ceiling material 1 was 820 g / m ² , and the sound absorption coefficient was 0.5 (250 Hz). The weight of the ceiling material 2 was 735 g / m ² , and the sound absorption coefficient was 0.5 (250 Hz).

[0020]

[Effect of the device]

 The ceiling material according to the present invention can be lightened while maintaining a satisfactory soundproof effect.

[0021]

[Brief description of drawings]

FIG. 1 is a sectional view of a ceiling material according to the present invention.

FIG. 2 is a sectional view of a ceiling material according to the present invention.

[Explanation of symbols]

 1 Sound Absorption Base Material 2 Foam Resin Coating Base Material 3 Adhesive Layer 4 Sound Absorption Layer 5 Resin Cotton 6 Skin Layer

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁵ Identification code Internal reference number FI technical display location B60R 13/08 7912-3D

Claims (1)

Claims for utility model registration: 1. One surface of the sound absorbing base material 1 is integrated with the foamed resin coating base material 2, and the other surface is integrated with the sound absorbing layer 4 via the adhesive layer 3. A lightweight molded ceiling material characterized in that, if necessary, a resin cotton 5 and a skin layer 6 are further provided, and then the resin coated on the base material is foamed.