JPH092176A - Molded ceiling material for vehicle and manufacture thereof - Google Patents

Abstract

PURPOSE: To provide a molded ceiling material for a vehicle to improve shock relaxing function of the molded ceiling material during collision of a vehicle and meanwhile, reduce a manufacturing cost and improve workability and to provide manufacturing method thereof. CONSTITUTION: A molded ceiling material for a vehicle is a molded ceiling material having a pad material 1. Formation of the molded ceiling material for a vehicle is such that ribs 10 are formed on a given portion of the pad material 1 of which a front part 2, a rear part or a side part 4 of the molded ceiling material is formed.

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 for manufacturing the molded ceiling material, and more particularly, a molded ceiling material for a vehicle having an improved impact absorbing function at a side surface portion, a front surface portion or a rear surface portion in the event of a vehicle collision. And an invention relating to a manufacturing method thereof.

[0002]

[Meaning of main terms] In this specification, "pad material"
The term "one of the members forming the molded ceiling material" means a member arranged over the entire surface of the molded ceiling material.

[0003]

2. Description of the Related Art Conventionally, a molded ceiling material for a vehicle having a structure as shown in FIG. 10 (A) has been known. That is, the molded ceiling material 100 was attached to the vehicle roof 8 through the mounting portion 36 and the rail roof side inner 34. As shown in FIG. 10B, the molded ceiling material 100 functions as a skin 102 forming the outer surface of the molded ceiling material, a glass chop 104 for ensuring the strength of the molded ceiling material, and a pad material. The thermoform 106 that fulfills the requirements is formed in the order of a sandwich-like layered structure, and a hot melt film 108 for joining these layered structures is inserted and heated, and then press-molded to form a molded ceiling material. Was formed. By the way, in recent years, vehicle safety measures have become of great concern, but regarding the measures against the collision in the front-rear direction or the side direction of the vehicle, in the conventional molded ceiling material, as shown in FIG. The cushion 110, which is separate from the molded ceiling material, is attached to the front and rear surface portions and side surface portions of the vehicle, and when the passenger's head hits the front and rear surface portions and side surface portions of the molded ceiling material during a vehicle side collision, the impact Was absorbed and relaxed by the cushion 110 to protect passengers.

[0004]

However, according to the conventional molded ceiling material having such a structure, although the molded ceiling material has an excellent shock absorbing function, the molded ceiling material is used for cushioning the front and rear surface portions and side surface portions of the ceiling at the time of collision. Since cushions that are separate from the molded ceiling material are attached to the front and rear surface portions and side surface portions of the material, there is a problem that the number of parts increases, work efficiency decreases, and cost increases. Therefore, an object of the present invention is to provide a molded ceiling material for a vehicle, which improves the impact mitigation function of the molded ceiling material at the time of a vehicle collision, and has good manufacturing cost and workability during manufacturing, and a manufacturing method thereof. And

[0005]

In order to solve the above-mentioned problems, the present invention takes the following measures. The invention of claim 1 is a molded ceiling material for a vehicle having a pad material, wherein a rib is formed at a predetermined portion of the pad material forming a front surface portion, a rear surface portion or a side surface portion of the molded ceiling material. It is a molded ceiling material for vehicles, which is characterized in that The invention of claim 2 is a method for manufacturing a molded ceiling material for a vehicle by pressurizing and molding at least a pad material using an upper mold and a lower mold, wherein the upper mold or the lower mold is manufactured. A molded ceiling material for a vehicle, wherein a rib molding portion for forming a rib is provided at a predetermined portion of the pad material forming a front surface portion, a rear surface portion or a side surface portion of the molded ceiling material. Is a manufacturing method. The invention of claim 3 is
The method for manufacturing a molded ceiling material for a vehicle according to claim 2, wherein the pad material is made of a foaming material and is heated for a predetermined time before or during the pressurization.

[0006]

According to the first aspect of the present invention, when the vehicle collides and the occupant collides with the ceiling, the ribs formed on the pad material at the front surface portion, the rear surface portion or the side surface portion of the molded ceiling material are provided at the time of collision. The shock is effectively absorbed, and the passenger's injury or the like can be effectively prevented. According to the second aspect of the present invention, when at least the pad material is pressed and molded using the upper mold and the lower mold, the rib molding portion provided on the upper mold or the lower mold allows the front surface portion of the molded ceiling material to be formed. A rib is formed at a predetermined portion of the pad material forming the rear surface portion or the side surface portion. As a result, a molded ceiling material capable of effectively absorbing the impact at the time of a vehicle collision is manufactured. According to the invention of claim 3, in the invention of claim 2, foaming or deformation is promoted by heating the pad material having a foamable material for a predetermined time during pressurization by the upper mold and the lower mold, Molding will be easily performed. At this time, the pad material is foamed and can sufficiently reach the rib molding portion, so that the ribs can be easily formed.

[0007]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A molded ceiling material for vehicles and a method of manufacturing the same, which are embodiments embodying the present invention, will be described below with reference to the drawings. Since the main feature of the present invention is the pad material, the description of the members such as the skin and the base material that constitute the actual molded ceiling will be appropriately omitted and described. First, for the molded ceiling material of this example,
The structure of the pad material 1 will be mainly described. As shown in FIG. 1, the pad material 1 includes an upper surface portion 6 that forms a ceiling surface of a vehicle.
And a front surface portion 2 integrally formed with the upper surface portion 6, a rear surface portion 3 and a side surface portion 4 which are not shown for convenience. They are,
When the molded ceiling material is assembled to the vehicle roof, the upper surface portion, the front surface portion, the rear surface portion, and the side surface portion of the vehicle ceiling are formed, respectively. Note that in FIG. 1, the pad material 1 is shown upside down for convenience of illustration.

As the material used for the pad material, for example, urethane foam, polyethylene foam, polypropylene foam, vinyl chloride foam, polystyrene foam or the like foamable material excellent in shock absorption. is there. From the viewpoint of shock absorption, it is particularly preferable to use a semi-hard urethane foam, a soft urethane foam or the like. Also,
At the time of molding, it is possible to mix glass fibers into the above material to improve the strength characteristics, or to mix, for example, felt or the like to improve the molding characteristics and weight characteristics in addition to the impact relaxation function.

Now, in FIG. 1, a rib 10 is integrally formed with the pad material 1 on the front surface portion 2 of the pad material 1. The rib 10 is a member for improving a shock absorbing function at the time of collision when a vehicle collides with and a passenger collides with the ceiling. That is, the rib 10 is crushed by the body of the occupant thrown out at the time of the collision, and the energy of impact is absorbed, whereby the occupant's injury is effectively prevented. In FIG. 1, the rib 10 is a pad material 1.
Although it is formed on the front face portion 2 of the above, it can be formed on the side face portion 4 as well as the rear face portion (not shown) in addition to the front face portion 2, and it can be arbitrarily determined whether to form on any one or a plurality of portions thereof. Is. Further, in FIG. 1, the rib 10 is a pad material 1.
Although it is formed from the front surface portion 2 to the front edge of the upper surface portion 6, it may be formed only within the range of the front surface portion 2 without such a configuration. In addition, after forming the pad material, the rib formed as a separate body may be joined to the pad material. Furthermore, the number, shape, thickness, etc. of the ribs 10 are not particularly limited, and can be arbitrarily selected based on, for example, the vehicle application, vehicle class, etc.

The molded ceiling material of this embodiment is constructed by joining a skin material and a base material (not shown) to the pad material 1. The skin material is a member of the molded ceiling material that is arranged on the inside of the vehicle, and is formed by using a material such as vinyl chloride, flicker leather, or non-woven fabric. The base material is a member for ensuring the shape of the molded ceiling material, and for example, a mixture of felt and thermosetting resin, a liner using PP material, a mixture of glass fiber and thermosetting resin, and the like are used.

Thus, the molded ceiling material 1a of this embodiment is constructed. Regarding the mounting of the molded ceiling material 1a to the vehicle roof, the side surface portion of the molded ceiling material 1a will be exemplarily described. As shown in FIG.
Is attached to the rail roof side inner 32 provided on the lower portion of the roof 8 for positioning, and the mounting portion 36 is mounted on the opening trim 34. The mounting of the front and rear surface portions of the molded ceiling material 1a is substantially the same, and the description thereof will be omitted.

When the molded ceiling material 1a is attached to the vehicle roof, the ribs 1 can effectively protect the body of the occupant, especially the head, in the event of a vehicle collision, as shown by the hatched portion in FIG.
0 will be placed. That is, the molded ceiling material 1a in FIG. 3 has a structure in which the ribs 10 are provided on each of the front surface portion 2, the side surface portion 4, and the rear surface portion 3. Further, since the rib 10 is not provided on the upper surface portion 6, the vehicle height does not unnecessarily increase.

Next, a method of manufacturing such a molded ceiling material will be described. The first manufacturing method is a case where a semi-hard urethane foam is used as the pad material. In this case, as shown in FIG. 4, the pad material 12 is attached to the clamp 14 and is pressed by the upper mold 16 and the lower mold 18 to perform molding.

In the present embodiment, rib forming portions 20 are provided in the upper mold 16 at positions where the pad material 12 is pressed to form the front surface and the rear surface of the formed ceiling material. As shown in FIG. 5, the rib forming portion 20 includes a plurality of rib forming grooves 2.
1, the rib 10 (see FIG. 1) is formed at a predetermined portion of the pad material through the rib forming groove 21. First, as shown in FIG. 6, the upper die 16 is lowered and the pad material 12 is pressed in contact with the lower die 18. Then, the material 12 for the pad is kept for a predetermined time while maintaining the pressurized state.
Heat. This is a process for promoting the foaming of the semi-rigid urethane foam, which is the material for the pad material, and improving the moldability, and the foamed material surely enters the rib forming groove 21 to form the rib. Become. Of course, when it is desired to form a rib at a predetermined portion of the pad material 10 forming the side surface portion of the molded ceiling material, the rib molding portion 2 is formed at a corresponding portion of the upper mold 16.
You can set 0.

Regarding the heating conditions, in this embodiment, the upper portion of the pad material is 200 ° C. and the lower portion is 300 ° C.
It was heated for about 50 seconds. The heating conditions can be arbitrarily set within a range where molding can be reliably performed. Further, in this embodiment, the heating is performed together with the pressurization by the upper mold 16 and the lower mold 18. However, the heating is first performed to sufficiently foam the pad material, and then the upper mold 16 and the lower mold 18 are used. It may be configured to apply pressure.

Thus, the pressure applied by the upper mold 16 and the lower mold 18 is released, and the molded ceiling material 1a is manufactured. For convenience of description and illustration, the description of the skin of the molded ceiling material is omitted, but in the present embodiment, the skin or the like is set in advance between the upper mold 16 and the lower mold 18 and hot, for example, when pressing. Any bonding method such as a method of bonding the material for the pad material via a melt film or the like, a method of bonding the material for the pad material after molding, or the like can be adopted.

Next, the second manufacturing method will be described.
This is a case where a soft urethane foam is used as the pad material. In this case, as shown in FIG. 8, the pad material 22 in a fluid state is injected into the lower mold 30 by using the injection machine 24. Then, as shown in FIG.
Is a method of foaming the pad material 22 and then molding the same, and is generally called integral foam molding. Also in this case, the upper mold 28
A rib molding portion (not particularly shown) is provided at a predetermined portion of.

In both the first manufacturing method and the second manufacturing method of this embodiment, the rib molding portion is provided in the upper mold, but it may be provided in the lower mold.
Furthermore, the method for manufacturing a molded ceiling material according to this embodiment is characterized in that ribs are formed at predetermined portions of the pad material,
It is possible to adopt various molding methods within the range of such a constitution. For example, reaction injection molding (RIM; Reaction) in which raw materials are discharged and mixed by a high-pressure injection machine, and then injected and injected into a mold to cause reaction solidification in a heated mold.
injection molding) or reinforced reaction injection molding (R-RIM; Reinforce) in which a reinforcing material such as glass fiber is mixed with urethane to improve strength characteristics.
d RIM).

[0019]

According to the present invention, the shock absorbing function of the molded ceiling material at the time of a vehicle collision is improved, while the manufacturing cost and the workability at the time of manufacturing are excellent, and the manufacturing method thereof. Will be provided.

[Brief description of drawings]

FIG. 1 is a perspective view showing a structure of a pad portion of a molded ceiling material of this embodiment.

FIG. 2 is a front sectional view showing a structure when the molded ceiling material of the present embodiment is attached to a vehicle roof.

FIG. 3 is a perspective view showing a structure of the molded ceiling material of the present embodiment mounted on a vehicle roof as viewed from the vehicle interior.

FIG. 4 is a front cross-sectional view showing a method of manufacturing the molded ceiling material of this embodiment when a semi-hard urethane foam is used as the pad material.

FIG. 5 is a perspective view showing a detailed structure of a rib forming portion.

FIG. 6 is a front cross-sectional view showing a method of manufacturing the molded ceiling material of this embodiment when a semi-hard urethane foam is used as the pad material.

FIG. 7 is a front cross-sectional view showing the structure of the molded ceiling material of this example that has been molded.

FIG. 8 is a front cross-sectional view showing the method for manufacturing the molded ceiling material of this example when a soft urethane foam is used as the pad material.

[Fig. 9] Similarly, a soft urethane foam is used for the pad material.
FIG. 7 is a front cross-sectional view showing the method for manufacturing the molded ceiling material of the present embodiment when using a rubber.

FIG. 10A is a front sectional view showing a structure of a conventional molded ceiling material, and FIG. 10B is a front sectional view showing a layered structure thereof.

[Explanation of symbols]

 1 Molded Ceiling Material 2 Front Part 3 Rear Part 4 Side Part 6 Top Part 10 Rib 20 Rib Formed Part 21 Rib Formed Groove

Claims (3)

[Claims] 1. A molded ceiling material for a vehicle having a pad material, wherein a rib is formed at a predetermined portion of the pad material forming a front surface portion, a rear surface portion or a side surface portion of the molded ceiling material. Molded ceiling material for vehicles characterized by. 2. A method for producing a molded ceiling material for a vehicle by pressurizing and molding at least a pad material using an upper mold and a lower mold, wherein the upper mold or the lower mold comprises: Manufacture of a molded ceiling material for a vehicle, characterized in that a rib molding portion for forming a rib is provided at a predetermined portion of the pad material forming a front surface portion, a rear surface portion or a side surface portion of the molded ceiling material. Method. 3. The method for manufacturing a molded ceiling material for a vehicle according to claim 2, wherein the material for the pad material is a foamable material and is heated for a predetermined time before or during the pressurization. .