Panel-type sunshade and automotive sunshade device including the panel-type sunshade

Abstract

This invention focuses on the characteristics of semi-rigid foamed urethane and provides a panel-type sunshade and an automotive sunshade device using the panel-type sunshade, wherein the rigidity of the panel-type sunshade is further improved by impregnating at least a layer of semi-rigid foamed urethane containing the semi-rigid foamed urethane with a thermosetting resin. The sunshade (40) is formed by sequentially stacking an outer skin member (40b), a core member (40a), and an inner skin member (40c), wherein the core member (40a) is formed by stacking a resin-impregnated semi-rigid foamed urethane layer (41) between two glass fiber pads (42, 43).

Description

Technical Field

[0001] This invention relates to a panel-type sunshade and a car sunshade device including the panel-type sunshade. Background Technology

[0002] Generally speaking, lightweight panel sunshades are ideal for operation. For example, in the case of panel sunshades being installed in automobiles as sunshade devices, in recent years, from the perspective of improving the fuel efficiency of said automobiles, there has been a demand for lightweight panel sunshades. Furthermore, in order to maintain its panel shape well, the sunshade is required to be a robust sunshade with rigidity that is not easily deformed.

[0003] Based on these requirements, in the past, as a type of panel sunshade, the sunshade for a car sunroof described in Patent Document 1 below has been disclosed.

[0004] To maintain both light weight and rigidity while retaining its panel-like shape, the sunshade employs a semi-rigid foamed urethane layer and two resin-impregnated fiberglass pads as the core component forming materials. With this forming material, the core component of the sunshade is formed by laminating the semi-rigid foamed urethane layer between the two resin-impregnated fiberglass pads.

[0005] In the core component, the two resin-impregnated fiberglass pads are formed by impregnating a liquid thermosetting resin into a fiberglass pad and then curing it. Therefore, although the two resin-impregnated fiberglass pads contribute to the increased weight when manufacturing the sunshade, they meet the requirement of high rigidity for the sunshade.

[0006] On the other hand, since the semi-rigid foamed urethane layer is lightweight, further weight increase as a core component can be suppressed. Furthermore, the semi-rigid foamed urethane layer possesses the flexibility of a material suitable for the core component of a sunshade, thus forming the core component together with two resin-impregnated glass fiber pads.

[0007] Thus, in the core component, one of the two resin-impregnated glass fiber pads has a skin layer formed of a skin material laminated from its surface side, while the other resin-impregnated glass fiber pad has an inner skin layer formed of an inner skin material laminated from its back side.

[0008] In this way, an outer skin layer, a resin-impregnated fiberglass pad, a semi-rigid foamed urethane layer, another resin-impregnated fiberglass pad, and an inner skin layer are layered to form a multilayer laminate. The multilayer laminate thus formed is compressed and shaped using a pressing mold under heat and pressure, thereby forming a sunshade.

[0009] Existing technical documents

[0010] Patent documents

[0011] [Patent Document 1] Japanese Patent No. 3592274 Summary of the Invention

[0012] [The problem the invention aims to solve]

[0013] Furthermore, in the sunshade constructed as described above, the two resin-impregnated fiberglass pads are formed by impregnating the fiberglass pads with liquid thermosetting resin and then hardening them, as described above.

[0014] In order to further improve the rigidity of the resin-impregnated glass fiber pad during the impregnation process, it is desirable to increase the weight per unit area of ​​the liquid thermosetting resin impregnated in the glass fiber pad.

[0015] However, while the rigidity of the sunshade is primarily ensured by the two resin-impregnated fiberglass pads, as mentioned above, the two fiberglass pads themselves contribute to the weight increase. Therefore, from a lightweighting perspective, the weight per unit area of ​​each of the two fiberglass pads should ideally be as low as possible.

[0016] Given this situation, the weight per unit area of ​​the liquid thermosetting resin impregnated in the fiberglass pad is inevitably limited. This is why it cannot meet the recent demands for further increasing the rigidity and strength of sunshades as panels.

[0017] Therefore, in order to address the above situation, the present invention aims to provide a panel-type sunshade and an automotive sunshade device including the panel-type sunshade, taking into account the characteristics of semi-rigid foamed urethane, wherein the panel-type sunshade further improves rigidity by impregnating at least a semi-rigid foamed urethane layer containing the semi-rigid foamed urethane with a liquid thermosetting resin and hardening it.

[0018] [Technical means to solve the problem]

[0019] In addressing the above problems, the panel-type sunshade of the present invention includes:

[0020] Skin component, inner skin component, and core component stacked between the skin component and the inner skin component.

[0021] In the aforementioned panel-type sunshade,

[0022] The core component includes two glass fiber pads and a resin-impregnated semi-rigid foamed urethane layer laminated between the two glass fiber pads.

[0023] The resin-impregnated semi-rigid foamed urethane layer is formed by impregnating the semi-rigid foamed urethane layer entirely with liquid thermosetting resin and then curing the liquid thermosetting resin.

[0024] According to this structure, the core component, as described above, comprises two glass fiber pads and a resin-impregnated semi-rigid foamed urethane layer laminated between the two glass fiber pads. Here, the resin-impregnated semi-rigid foamed urethane layer is formed by impregnating the semi-rigid foamed urethane layer entirely with a liquid thermosetting resin and then curing the liquid thermosetting resin.

[0025] In addition, in the core component, the two glass fiber pads have higher rigidity in their structure than the semi-rigid foamed urethane layer, but the two glass fiber pads are heavier than the semi-rigid foamed urethane layer containing glass fibers in terms of their respective glass fiber content.

[0026] Therefore, from the perspective of lightweighting the sunshade, the increase in the weight per unit area of ​​the two fiberglass pads is naturally limited. Consequently, the increase in the weight per unit area of ​​the liquid thermosetting resin impregnated in the two fiberglass pads is also limited. This means that, in the case of impregnating two fiberglass pads with liquid thermosetting resin and then curing them to create two resin-impregnated fiberglass pads, the rigidity of the panel sunshade will not be further enhanced.

[0027] In contrast, the semi-rigid polyurethane foam layer, formed by the semi-rigid polyurethane foam material, is lightweight. Therefore, even from the perspective of lightweighting sunshades, the area weight per unit area of ​​the semi-rigid polyurethane foam layer can be increased. This means that when forming a resin-impregnated semi-rigid polyurethane foam layer, the area weight per unit area of ​​the thermosetting resin impregnated in the semi-rigid polyurethane foam layer can be significantly increased compared to the total area weight per unit area of ​​the thermosetting resin that can be impregnated in two glass fiber pads.

[0028] In this context, the core component is formed by laminating a resin-impregnated semi-rigid foamed urethane layer between two glass fiber pads. This significantly enhances the rigidity of the core component, thereby greatly strengthening the rigidity of the panel-type sunshade. Consequently, the panel-type sunshade will not deform even under external forces and can maintain its original panel shape well.

[0029] Furthermore, this invention is characterized by the following:

[0030] The skin component includes the skin layer and the skin layer side adhesive layer.

[0031] The lining components include the lining layer and the lining layer side bonding layer.

[0032] In the core component, one of the two fiberglass pads is bonded to the skin layer through the skin layer side adhesive layer, facing the skin layer in a manner that is separated from the skin layer side adhesive layer. On the other hand, the other fiberglass pad is bonded to the inner skin layer through the inner skin layer side adhesive layer, facing the inner skin layer in a manner that is separated from the inner skin layer side adhesive layer.

[0033] In this way, by specifically specifying the structure of the outer skin component and the inner skin component, and specifically specifying the layered structure between the outer skin component and the inner skin component of the core component, the effects of the present invention described above can be achieved more specifically.

[0034] In addition, this invention is characterized by the following: in the resin-impregnated semi-rigid foamed urethane layer, the liquid thermosetting resin impregnated in the semi-rigid foamed urethane layer has a unit area weight within a specified range.

[0035] By specifically specifying the unit area weight of the liquid thermosetting resin in this way, the rigidity of the core component can be ensured more precisely; in other words, the rigidity of the panel-type sunshade can be ensured more precisely. As a result, the effects of the present invention described above can be achieved more precisely.

[0036] Furthermore, in this invention, the liquid thermosetting resin impregnated in the semi-rigid foamed urethane layer is characterized by having a specified unit area weight range of 150 g / m². 2 ~500g / m 2 .

[0037] Accordingly, the effects of the present invention can be achieved more specifically.

[0038] Furthermore, in this invention, the weight per unit area of ​​the liquid thermosetting resin is more preferably 200 g / m². 2 ±20g / m 2 Values ​​within the range.

[0039] Furthermore, the present invention is characterized in that: in the panel-shaped sunshade,

[0040] The core component comprises two resin-impregnated glass fiber pads.

[0041] The two resin-impregnated glass fiber mats are formed by impregnating the corresponding glass fiber mats of the two mats with liquid thermosetting resin and then curing the liquid thermosetting resin.

[0042] A resin-impregnated semi-rigid foamed urethane layer is stacked between two resin-impregnated glass fiber pads.

[0043] Accordingly, the core component not only has a resin-impregnated semi-rigid foamed urethane layer, but also two glass fiber pads in the form of two resin-impregnated glass fiber pads. In other words, the core component is formed to have rigidity in addition to the rigidity of the resin-impregnated semi-rigid foamed urethane layer, with the additional rigidity of the two resin-impregnated glass fiber pads.

[0044] Therefore, the rigidity of the panel-shaped sunshade can be further enhanced. As a result, the panel-shaped sunshade can maintain its further enhanced panel shape.

[0045] The present invention configured in this way can be:

[0046] In the core component, one of the two resin-impregnated fiberglass pads is bonded to the skin layer through the skin layer side adhesive layer, with the skin layer side adhesive layer facing each other. On the other hand, the other resin-impregnated fiberglass pad is bonded to the inner skin layer through the inner skin layer side adhesive layer, with the inner skin layer side adhesive layer facing each other.

[0047] In this way, even though the core component is a structure in which resin-impregnated semi-rigid foamed urethane layers are stacked between two resin-impregnated glass fiber pads, the effects of the present invention can be more specifically achieved by specifically specifying the structure of the skin component and the inner skin component, and specifically specifying the stacked structure between the skin component and the inner skin component of the core component as described above.

[0048] Alternatively, the present invention may be characterized in that: in two resin-impregnated glass fiber pads, each glass fiber pad has a weight per unit area within a first predetermined range, and the liquid thermosetting resin impregnated in each glass fiber pad has a weight per unit area within a second predetermined range.

[0049] In the resin-impregnated semi-rigid foamed urethane layer, the liquid thermosetting resin impregnated in the semi-rigid foamed urethane layer has a unit area weight within a third specified range.

[0050] By specifically specifying the unit area weight of the resin-impregnated semi-rigid foamed urethane layer, the two resin-impregnated glass fiber pads, and the liquid thermosetting resin of the core component, the rigidity of the core component can be more specifically ensured; in other words, the rigidity of the panel-type sunshade can be more specifically ensured. As a result, the effects of the invention can be more specifically achieved.

[0051] Here, in this invention, it can be:

[0052] The first specified range of the unit area weight of each of the two fiberglass mats is 100 g / m². 2 ~500g / m 2,

[0053] The second specified range of the unit area weight of the liquid thermosetting resin impregnated in each glass fiber pad is 20 g / m². 2 ~50g / m 2 ,

[0054] The third specified range of the unit area weight of the liquid thermosetting resin impregnated in the semi-rigid foamed urethane layer is 150 g / m². 2 ~500g / m 2 .

[0055] The effects of the present invention can be achieved more specifically by specifying the range of unit area weight of each of the two glass fiber pads, and specifically specifying the range of unit area weight of each glass fiber pad and the semi-rigid foamed urethane layer impregnated with liquid thermosetting resin.

[0056] Alternatively, in this invention, it can be:

[0057] The weight per unit area of ​​the liquid thermosetting resin impregnated in each glass fiber pad is more preferably 30 g / m². 2 ±3g / m 2 Values ​​within 1000,

[0058] The weight per unit area of ​​the liquid thermosetting resin impregnated in the semi-rigid foamed urethane layer is more preferably 200 g / m². 2 ±20g / m 2 Values ​​within the range.

[0059] In addition, in this invention, the liquid thermosetting resin may also be a liquid isocyanate.

[0060] In addition, the automotive panel sunshade device of the present invention is

[0061] Two guide rails are applied to the window, which is formed in the sunroof of the car, for opening and closing.

[0062] In the panel-type sunshade device,

[0063] Includes panel-type sunshades and multiple sliding components.

[0064] The panel-type sunshade includes an outer skin component, an inner skin component, and a core component stacked between the outer skin component and the inner skin component.

[0065] The core component includes two glass fiber pads and a resin-impregnated semi-rigid foamed urethane layer laminated between the two glass fiber pads.

[0066] The resin-impregnated semi-rigid foamed urethane layer is formed by impregnating the semi-rigid foamed urethane layer entirely with liquid thermosetting resin and then curing the liquid thermosetting resin.

[0067] Multiple sliding components are installed on at least the rear side of the left and right edges of the panel-type sunshade.

[0068] If configured in this way, the panel-type sunshade includes a core component formed by laminating a resin-impregnated semi-rigid foamed urethane layer between two glass fiber pads. Therefore, based on the premise that this type of panel-type sunshade can achieve the above-described effects of the panel-type sunshade of the present invention, a sunshade device including the aforementioned panel-type sunshade can be provided.

[0069] Furthermore, the present invention is characterized in that: in the automotive panel sunshade device,

[0070] The core component comprises two resin-impregnated glass fiber pads.

[0071] The two resin-impregnated glass fiber mats are formed by impregnating the corresponding glass fiber mats of the two mats with liquid thermosetting resin and then curing the liquid thermosetting resin.

[0072] A resin-impregnated semi-rigid foamed urethane layer is stacked between two resin-impregnated glass fiber pads.

[0073] Multiple sliding components are installed on at least the rear side of the left and right edges of the panel-type sunshade.

[0074] According to this structure, the panel-type sunshade includes a core component formed by laminating a resin-impregnated semi-rigid foamed urethane layer between two resin-impregnated glass fiber pads. Therefore, based on the premise that this type of panel-type sunshade can achieve the aforementioned effects of the panel-type sunshade of the present invention, a sunshade device including the aforementioned panel-type sunshade can be provided.

[0075] Furthermore, the automotive sunshade device of the present invention is characterized by the following features:

[0076] Panel-type sunshades include:

[0077] A flat central portion; front and rear end portions extending forward and backward from the flat central portion; and left and right side edges extending to the left and right sides from the flat central portion.

[0078] The left and right side edges include their respective front portions and all other portions besides the aforementioned front portions.

[0079] The remaining portions are formed with a compression rate higher than that of the central portion of the flat plate, while the front portions are formed with a compression rate lower than that of the remaining portions.

[0080] The rear end is formed by compression at a higher rate than that of the flat central portion.

[0081] The front end is compressed at a higher compression rate than the flat central part, and is formed into a curved shape that gently bulges forward towards the inner skin member.

[0082] If configured in this way, in a panel-type sunshade that is a compression-formed laminate, the front end of the sunshade is formed into a curved shape that gently bulges forward and curves toward the inner skin member. Therefore, the core member is not exposed on the outer skin member side, and the aesthetics of the panel-type sunshade can be well maintained.

[0083] Furthermore, as mentioned above, the compression ratios of the remaining portions of the left and right side edges (excluding the front portions) and the front and rear side portions are higher than that of the planar central portion. Therefore, the rigidity of the corresponding portions in the core member that correspond to the remaining portions and the corresponding portions that correspond to the front and rear side portions also increases. Consequently, the outer periphery of the panel-shaped sunshade becomes harder. As a result, when the sunshade device is opened and closed, the panel-shaped sunshade will not deform even under external force, and can maintain its original panel shape well.

[0084] Furthermore, as described above, each front portion of the left and right side edges is formed with a lower compression ratio than the remaining portions of the left and right side edges. Therefore, if each front portion is used as a support portion instead of each front sliding member, and sliding members are assembled at each rear portion of the left and right side edges, then when the sunshade device is installed on the sunroof of a car via the left and right guide rails, the panel-type sunshade can allow each support portion and each sliding member to slide smoothly along the interior of each of the left and right guide rails without using each front sliding member. Attached Figure Description

[0085] Figure 1 This is a schematic schematic plan view of a car that uses the first embodiment of the sunshade device of the present invention, obtained by partial breaking.

[0086] Figure 2 This indicates the sunshade of the sunshade device is in the open state. Figure 1 A schematic, approximate plan view of a car.

[0087] Figure 3 It is in response to Figure 1 The sunshade device is indicated in its state when viewed from its surface (the side of the car interior). Figure 1 A schematic outline of the sunshade device.

[0088] Figure 4 It is in response to Figure 1 The sunshade device is indicated when viewed from its rear (side of the car roof) side. Figure 1 A schematic rear view of the sunshade device.

[0089] Figure 5 It is along Figure 3 Enlarged longitudinal section view of the 5-5 line sunshade device.

[0090] Figure 6 Yes Figure 1 A rough surface diagram of the sunshade obtained by observing its surface side.

[0091] Figure 7 Yes Figure 1 A rough rear view of the sunshade, obtained by observing it from the back side.

[0092] Figure 8 It is along Figure 6 Enlarged longitudinal section of the sunshade along line 8-8.

[0093] Figure 9 It is represented by circle A Figure 8 A magnified partial cross-sectional view of a portion of the sunshade.

[0094] Figure 10 This is an enlarged exploded perspective view of the sunshade before resin impregnation in the core component of the first embodiment.

[0095] Figure 11 It is a graph showing the maximum load and flexural elastic gradient relative to the test specimen and the comparison specimen in the first embodiment.

[0096] Figure 12 This is a schematic structural diagram showing the bending strength testing device in the first embodiment.

[0097] Figure 13 This is an enlarged longitudinal sectional view of the sunshade in the second embodiment of the sunshade device of the present invention.

[0098] Figure 14 It is represented by circle B Figure 13 A magnified partial cross-sectional view of a portion of the sunshade.

[0099] Figure 15 This is a schematic rear view of the sunshade in the third embodiment of the sunshade device of the present invention, observed from the rear side.

[0100] Figure 16 This is an enlarged longitudinal cross-sectional view of the sunshade in the third embodiment.

[0101] Figure 17 It means in Figure 15 A magnified partial side view of the sunshade device as seen from the direction of arrow C.

[0102] Figure 18 It is along Figure 15 A cross-sectional view of line 18-18.

[0103] Figure 19 It is along Figure 15 A cross-sectional view of line 19-19.

[0104] Figure 20 It is along Figure 15 A cross-sectional view of line 20-20. Detailed Implementation

[0105] Hereinafter, various embodiments of the present invention will be described with reference to the accompanying drawings.

[0106] (First Implementation)

[0107] Figure 1 This illustration shows a first embodiment of the invention applied to a sunshade device for an automobile. The automobile includes a body 10, and a window WD is provided on the roof 20 of the body 10. (As shown...) Figure 1 or Figure 2 As shown, the window WD is formed by a transparent panel embedded in an opening 21a (hereinafter also referred to as the outer panel opening 21a) formed in the outer panel 21 of the roof 20. Furthermore, in this first embodiment, the sunshade device will be represented by the symbol SD.

[0108] In this first embodiment, the roof 20 having the window WD functions as a sunroof (hereinafter also referred to as sunroof 20) of the vehicle. Furthermore, the roof 20 is composed of an outer panel 21 and an inner panel (not shown) on its inner side, and an opening (hereinafter also referred to as inner panel opening) is formed in the inner panel at a location corresponding to the opening 21a of the outer panel. Additionally, in Figure 1 and Figure 2 In the diagram, the right and left sides correspond to the front and rear sides of the vehicle body 20, respectively.

[0109] The sunshade device SD is applied to the sunroof 20 of the vehicle. The sunshade device SD is slidably supported on the outer panel 21 (see reference) via left and right side guide rails 30 in a front-to-back direction, so as to face the window WD. Figure 1 or Figure 2 Furthermore, the left and right guide rails 30 are each formed in a U-shape in cross section. The left and right guide rails 30 are installed from the inner plate side along the left and right sides of the outer plate opening 21a of the outer plate 21, facing each other in the left and right direction at their respective elongated openings (see reference). Figure 1 ).

[0110] Thus, when the sunshade device SD blocks light from the vehicle interior through the window WD, it is located... Figure 1 The position shown (hereinafter also referred to as the shading position). Additionally, the sunshade device SD slides along the left and right guide rails 30 to allow light from the window WD to enter the vehicle interior. Figure 2 The position shown (hereinafter also referred to as the incident position). In addition, when the sunshade device SD is in the incident position, it is located between the outer panel 21 and the inner panel of the roof 20.

[0111] like Figures 3-5 As shown in any of the embodiments, the sunshade device SD includes a panel-type sunshade 40, a handle 50, and four sliding members 60. Figures 3-9 As shown in any of them, the panel-type sunshade 40 includes a core component 40a, an outer skin component 40b, and an inner skin component 40c, wherein the inner skin component 40c, the core component 40a, and the outer skin component 40b are stacked in sequence and formed into a sunshade 40 by pressing.

[0112] like Figure 9 As shown, the core component 40a includes a resin-impregnated semi-rigid foamed urethane layer 41 and two glass fiber pads 42 and 43, with the resin-impregnated semi-rigid foamed urethane layer 41 stacked between the two glass fiber pads 42 and 43. Furthermore, in this first embodiment, the glass fiber pad 42 is also referred to as the outer skin-side glass fiber pad 42, and the glass fiber pad 43 is also referred to as the inner skin-side glass fiber pad 43.

[0113] The resin-impregnated semi-rigid foamed urethane layer 41 is formed by impregnating a liquid thermosetting resin into the semi-rigid foamed urethane layer 41a (see reference). Figure 10 And it is formed by hardening it. In this first embodiment, Figure 10 An exploded perspective view shows the laminated structure formed by stacking the outer skin layer 45 and the barrier film 44, the glass fiber pad 42 on the outer skin side, the semi-rigid foamed urethane layer 41a before resin impregnation, the glass fiber pad 43 on the inner skin side, the adhesive film 46 and the inner skin layer 47 (corresponding to the laminated structure of the panel-type sunshade 40).

[0114] In the laminated structure, the barrier film 44 and the skin layer 45 constitute the skin component 40b (described later), the glass fiber pad 42 on the skin layer side, the semi-rigid foamed urethane layer 41a, and the glass fiber pad 43 on the inner skin layer side constitute the core component Nc before resin impregnation (corresponding to the core component 40a), and the adhesive film 46 and the inner skin layer 47 constitute the inner skin component 40c (described later).

[0115] The use of semi-rigid foamed urethane in the resin-impregnated semi-rigid foamed urethane layer 41, as described above, is based on the following.

[0116] Foamed urethanes are typically formed by foaming urethane to create either continuous or independent bubbles. The greater the number of continuous bubbles compared to the number of independent bubbles, the softer and more supple the foamed urethane, closely resembling a soft foamed urethane. Conversely, the greater the number of independent bubbles compared to the number of continuous bubbles, the harder and more rigid the foamed urethane, closely resembling a rigid foamed urethane.

[0117] Therefore, as a semi-rigid foamed urethane 41a for panel-type sunshades, it is ideal to use a foamed urethane (semi-rigid foamed urethane) formed by creating continuous and independent bubbles in the urethane, so as to have a hardness in the panel-type sunshade that corresponds to the rigidity that can well maintain the shape of the panel.

[0118] The semi-rigid foamed urethane layer 41a formed from this type of semi-rigid foamed urethane has excellent air permeability due to the presence of a large number of continuous air bubbles, and thus effectively functions as a key component of the core member 40a of the panel-type sunshade 40. Furthermore, because of the excellent air permeability of the semi-rigid foamed urethane layer 41a as described above, liquid thermosetting resin can also be easily impregnated into the semi-rigid foamed urethane layer 41a.

[0119] The semi-rigid foamed urethane layer 41a is formed in a layered form from semi-rigid foamed urethane having a unit area weight within a specified range. The specified unit area weight range refers to 100 (g / m²). 2 )~300(g / m 2 Within the specified unit area weight range, the lower limit is set at 100 (g / m²). 2 The reason for this is to prevent the semi-rigid foamed urethane layer 41a from becoming too soft and compromising its semi-rigidity suitable for panel-type sunshades. On the other hand, the upper limit is set at 300 (g / m²). 2 The reason for this is to prevent the semi-rigid foamed urethane layer 41a from becoming too rigid and compromising its semi-rigidity suitable for panel-type sunshades.

[0120] In addition, the resin impregnated in the semi-rigid foamed urethane layer 41a comprises a thermosetting resin, which is applied in liquid form from both sides of the semi-rigid foamed urethane layer 41a to its entire surface, and is impregnated in the semi-rigid foamed urethane layer 41a and cured, thereby forming a resin-impregnated semi-rigid foamed urethane layer 41.

[0121] Thus, the resin-impregnated semi-rigid foamed urethane layer 41 is formed throughout the entire layer, exhibiting high rigidity (see reference) and being able to maintain its original plate shape well without being affected by external forces. Figure 9 ).

[0122] In this first embodiment, isocyanate can be cited as an example of the thermosetting resin. Furthermore, the isocyanate content relative to the semi-rigid foamed urethane layer 41a is set to a value within a specified range per unit area weight. Here, the specified range per unit area weight is set such that the resin impregnation of the semi-rigid foamed urethane layer 41 can cover the entire layer, achieving high rigidity such as maintaining its original sheet shape (sheet shape) without being affected by external forces.

[0123] In this first embodiment, the isocyanate impregnated in the semi-rigid foamed urethane layer 41a has a specified area weight range of 100 g / m². 2 )~500(g / m 2 Within the specified range of weight per unit area, the lower limit is set at 100 g / m². 2 The reason is that when it is less than 100 (g / m 2 When the resin impregnation of the semi-rigid foamed urethane layer 41 is insufficient, there is a concern that the original plate shape cannot be well maintained. Furthermore, the upper limit is set to 500 (g / m²). 2 The reason is that if it exceeds 500 (g / m³) 2 If liquid isocyanate seeps out from the surface of the impregnated semi-rigid foamed urethane layer 41a (resin-impregnated semi-rigid foamed urethane layer 41), there is concern that it may damage the appearance of the resin-impregnated semi-rigid foamed urethane layer 41.

[0124] Furthermore, the two glass fiber mats 42 and 43 are formed by interlacing multiple glass fibers to create a mat shape. Thus, the two glass fiber mats 42 and 43 are structures that can exhibit good rigidity based on the structure of interlacing multiple rigid glass fibers.

[0125] Thus, the outer skin side glass fiber pad 42 of the two glass fiber pads 42 and 43 is stacked along the surface (outer skin side) of the resin-impregnated semi-rigid foamed urethane layer 41. On the other hand, the inner skin side glass fiber pad 43 is stacked along the back side (inner skin side) of the resin-impregnated semi-rigid foamed urethane layer 41.

[0126] In this way, the two glass fiber pads 42 and 43 on the epidermal layer side and the lining layer side, based on their respective rigidity, play an auxiliary role in maintaining the resin-impregnated semi-rigid foamed urethane layer 41 in its original plate shape by clamping the resin impregnated semi-rigid foamed urethane layer 41.

[0127] Here, the function of the core component 40a in the panel-type sunshade will be explained. As its name suggests, the panel-type sunshade refers to a sunshade with a panel shape, i.e., a panel-like shape. The panel-type sunshade is constructed in the form of a device and is mounted on the sunroof 20 (roof 20) of a car. Based on this, the opening and closing of the sunroof 20 requires a lightweight panel shape with high rigidity that is easy to move along the outer panel 21 of the sunroof 20 in the front-rear direction and is not easily deformed.

[0128] To meet these requirements, the core component 40a, which is the main component of the sunshade 40 in the panel-type sunshade device SD, must have high rigidity. Therefore, in this first embodiment, as described above, the core component 40a is formed by a laminated structure of a resin-impregnated semi-rigid foamed urethane layer 41 and two glass fiber pads 42, 43.

[0129] Here, the resin-impregnated semi-rigid foamed urethane layer 41, as described above, is formed by impregnating the semi-rigid foamed urethane layer 41a with a liquid isocyanate, which is a type of liquid thermosetting resin, and then curing the liquid isocyanate.

[0130] The reason for setting the impregnation object of liquid isocyanate as a semi-rigid foamed urethane layer 41a instead of two glass fiber pads 42, 43 is as follows.

[0131] In recent years, there has been a growing demand for enhanced rigidity in panel-type sunshades. However, while the two fiberglass pads 42 and 43 have higher rigidity structurally than the semi-rigid foamed urethane layer 41a, they contain fiberglass. Therefore, the two fiberglass pads 42 and 43 are significantly heavier than the semi-rigid foamed urethane layer 41a, which contains foamed urethane.

[0132] Therefore, from the perspective of lightweighting the sunshade 40, an increase in the weight per unit area of ​​each of the two fiberglass pads 42 and 43 would naturally be limiting. Consequently, an increase in the weight per unit area of ​​the liquid isocyanate impregnated in each of the two fiberglass pads 42 and 43 would also be limiting.

[0133] Furthermore, since each glass fiber pad 42, 43 is formed from multiple glass fibers, it does not possess the same air permeability as the semi-rigid foamed urethane layer 41a. Therefore, it is difficult for liquid isocyanate to penetrate both glass fiber pads 42, 43. Consequently, the total area weight of liquid isocyanate impregnated in the two glass fiber pads 42, 43 is significantly less than the area weight of liquid isocyanate impregnated in the semi-rigid foamed urethane layer 41a.

[0134] Thus, even if liquid isocyanate is impregnated in the two glass fiber pads 42 and 43 and hardened, it is impossible to increase the rigidity of the two glass fiber pads 42 and 43 to a level that can meet the requirements of recent years for reinforcing the panel-type sunshade.

[0135] In contrast, the semi-rigid foamed urethane layer 41a has good air permeability due to its foamed structure, making it easy for liquid isocyanate to penetrate. This means that the increase in the weight per unit area of ​​liquid isocyanate impregnated in the semi-rigid foamed urethane layer 41a is significantly easier compared to the case where it is impregnated in the two glass fiber pads 42 and 43.

[0136] In other words, the area weight per unit area of ​​the semi-rigid foamed urethane layer 41a can be increased more than that of each of the two glass fiber pads 42 and 43. Therefore, the area weight per unit area of ​​the liquid isocyanate impregnated in the semi-rigid foamed urethane layer 41a can be further increased compared to the area weight per unit area of ​​the liquid isocyanate impregnated in each of the two glass fiber pads 42 and 43.

[0137] Based on this situation, as described above, the specified unit area weight range of the isocyanate impregnated in the semi-rigid foamed urethane layer 41a is set to 100 (g / m²). 2 )~500(g / m 2 Furthermore, in this first embodiment, the isocyanate impregnated in the semi-rigid foamed urethane layer 41a has a more preferably area weight of 200 g / m². 2 ±20g / m 2 Values ​​within (e.g., 200g / m³) 2 ).

[0138] In view of the above, in this first embodiment, it is set so that the liquid isocyanate is uniformly impregnated in the semi-rigid foamed urethane layer 41a. Furthermore, as described above, the area weight of the semi-rigid foamed urethane layer 41a can be increased more than the area weight of each of the two glass fiber pads 42 and 43. Therefore, the area weight of the liquid isocyanate impregnated in the semi-rigid foamed urethane layer 41a can be further increased compared to the sum of the area weights of the liquid isocyanate in each of the two glass fiber pads 42 and 43.

[0139] Since the isocyanate is a thermosetting resin, if the liquid isocyanate impregnated in the semi-rigid foamed urethane layer 41a is cured as described above, a core member 40a of the sunshade 40 can be formed with significantly higher rigidity than the case where the liquid isocyanate is impregnated in each of the two glass fiber pads 42, 43 and cured.

[0140] Therefore, the rigidity of the resin-impregnated semi-rigid foamed urethane layer 41, formed by impregnating a semi-rigid foamed urethane layer 41a with liquid isocyanate as described above and then curing it, is significantly enhanced compared to the sum of the rigidities of the two glass fiber pads formed by impregnating and curing liquid isocyanate. This means that the requirement for enhanced rigidity of the sunshade described at the beginning of this specification can be adequately met.

[0141] like Figure 9 As illustrated, the skin component 40b includes a barrier film 44 and a skin layer 45. The barrier film 44 has adhesive and gas-tight properties, and the barrier film 44 has adhesive properties on both its front and back sides.

[0142] Accordingly, the barrier film 44, based on its adhesive properties, serves to bond the glass fiber pad 42 on the skin layer side to the skin layer 45. Additionally, based on its gas-sealing properties, the barrier film 44, when formed by compression molding into the sunshade 40, serves to seal the leakage of gas released from the resin-impregnated semi-rigid foamed urethane layer 41 to the outside.

[0143] The skin layer 45 is formed in a layered form from a specified skin material. The skin layer 45 is bonded and laminated along the glass fiber pad 42 on the skin layer side, with the resin-impregnated semi-rigid foamed urethane layer 41 facing each other, through a barrier film 44. Furthermore, the skin layer 44 faces the interior of the vehicle interior on its surface (the interior side). Examples of the specified skin material include, for instance, polyurethane foam laminated woven fabric, textiles, or needle-punched nonwoven fabric.

[0144] like Figure 9As illustrated, the inner skin component 40c includes an adhesive film 46 and an inner skin layer 47. The adhesive film 46, based on its adhesive properties, serves to bond the fiberglass pad 43 on the inner skin layer side to the inner skin layer 47. Furthermore, the adhesive film 46 performs an adhesive function on both its front and back sides.

[0145] The inner skin layer 47 is formed in a layered shape from a specified inner skin material. The inner skin layer 47 is bonded and layered along the glass fiber pad 43 on the inner skin layer side, with the resin-impregnated semi-rigid foamed urethane layer 41 facing each other, via an adhesive film 46. Examples of the specified inner skin material include polyester nonwoven fabric. In this first embodiment, the total unit area weight and total thickness of the sunshade 40 are, for example, 1430 g / m². 2 and 7.0mm.

[0146] A sunshade 40 formed by stacking layers as described above Figure 6 and Figure 7 As shown, it is composed of a flat central portion 40d, front and rear end portions 40e and 40f, and left and right side edges 40g and 40h. When the sunshade 40 constructed in this way is formed by pressing as described above, the sunshade 40 is compressed to form a shape as shown... Figure 6 and Figure 7 The surface and back shapes shown are as follows: Figure 8 The longitudinal section shape shown is a defined three-dimensional flat shape.

[0147] In this first embodiment, Figure 6 This diagram is an observation of the sunshade 40 from its surface (the interior side of the vehicle body 10). On the other hand, Figure 7 This diagram is taken from the back of the sunshade 40 (side of the sunroof 20). Furthermore, the surface of the outer skin layer 45 of the sunshade 40 (the interior side of the vehicle body 10) is referred to as the surface of the sunshade 40, and the back of the inner skin layer 47 of the sunshade 40 (side of the sunroof 20) is referred to as the back of the sunshade 40.

[0148] Here, the front and rear end portions 40e and 40f, and the left and right side edges 40g and 40h are compressed at a higher compression rate than the flat central portion 40d. Therefore, the front and rear end portions 40e and 40f, and the left and right side edges 40g and 40h, are rigid and have higher rigidity than the flat central portion 40d. Furthermore, in this first embodiment, the compression rates of the front and rear end portions 40e and 40f can be the same as, or higher than, or lower than, the compression rates of the left and right side edges 40g and 40h.

[0149] Thus, in the sunshade 40, the front end 40e of the front and rear end portions 40e and 40f is as follows: Figures 5-7 As shown in either of them, it extends forward from the front end of the flat central portion 40d. On the other hand, the rear end portion 40f is as shown in the figure. Figure 5 As shown, it is formed to extend from the rear end of the flat central portion 40d and protrude in a U-shape toward the inner skin member 40c. In this first embodiment, the rear end portion 40f is also referred to as the rear locking portion 40f. Furthermore, when the sunshade device SD reaches the rear sliding end, the rear locking portion 40f engages with the rear inner edge of the inner panel opening, restricting further rearward sliding of the sunshade device SD.

[0150] The left and right side edges 40g and 40h correspond to the left and right side edges of the sunshade 40. The left and right side edges 40g and 40h are as follows: Figure 6 and Figure 7 As shown, it is formed by extending outwards in opposite directions from the left and right edges of the flat central portion 40d.

[0151] Here, the left edge 40g has front and rear cutouts j for mounting two sliding members 60 (described later) respectively (see reference). Figure 6 These front and rear side cuts j are formed by cutting out the front and rear sides of the left edge 40g in a U-shape. On the other hand, the right edge 40h has front and rear side cuts j for mounting the remaining two sliding members 60 (see reference). Figure 6 These incisions on the front and back sides (j) are formed by U-shaped excision of the front and back sides of the right edge 40h.

[0152] The handle 50 is embedded in the narrow through hole h formed at the center of the front end side of the flat central part 40d in the left-right direction (refer to) Figures 6-8 (refer to) Figures 3-5 Here, the handle 50 is formed in a concave shape from the epidermal layer 45 side to the endodermal layer 47 side, so that it can be fitted into the narrow through hole h of the flat central portion 40d.

[0153] Thus, the occupant slides the sunshade 40 along the left and right guide rails 30 in the rearward direction via the handle 50 inside the vehicle body 10, thereby causing the sunshade device SD to slide along the guide rails 30 in the rearward direction. When the sunshade device SD is at the front sliding end, it closes the window WD via the sunshade 40. Conversely, when the sunshade device SD is at the rear sliding end, it opens the window WD via the sunshade 40. Furthermore, when the sunshade device SD closes the window WD, the sunshade 40 is in a closed state; conversely, when the sunshade device SD opens the window WD, the sunshade 40 is in an open state.

[0154] According to Figure 3 and Figure 4 It is understood that two of the four sliding members 60 are respectively assembled on the front and rear sides of the left edge 40g and the front and rear sides of the right edge 40h of the sunshade 40. Furthermore, in this first embodiment, the two sliding members 60 installed on the front and rear sides of the left edge 40g of the sunshade 40 are referred to as the left front sliding member 60 and the left rear sliding member 60. The two sliding members 60 installed on the front and rear sides of the right edge 40h of the sunshade 40 are referred to as the right front sliding member 60 and the right rear sliding member 60.

[0155] Specifically, the left front sliding member 60 is installed at the front cutout j formed at the left edge 40g of the sunshade 40 (refer to...). Figure 6 The rear cutout j formed by the left rear sliding member 60 being installed at the left edge 40g of the sunshade 40 (refer to...) Figure 6 Additionally, the right front sliding member 60 is installed at the right edge 40h of the sunshade 40, forming a right-side cutout j (see reference). Figure 6 The rear side cutout j formed by the right rear sliding member 60 being installed at the right side edge 40h of the sunshade 40 (refer to...) Figure 6 Furthermore, all four sliding members 60 have the same structure.

[0156] In this first embodiment constructed as described above, as stated above, the core component 40a of the sunshade 40 is formed of two glass fiber pads 42, 43 and a resin-impregnated semi-rigid foamed urethane layer 41 stacked between the two glass fiber pads 42, 43.

[0157] In the core component 40a, as described above, the resin-impregnated semi-rigid foamed urethane layer 41 is formed by uniformly impregnating the semi-rigid foamed urethane layer 41a with liquid isocyanate and then hardening it.

[0158] Here, regarding the unit area weight of liquid isocyanate impregnated in the semi-rigid foamed urethane layer 41a, with respect to the structure of the semi-rigid foamed urethane layer 41a as described above, it can be significantly increased compared to the sum of the unit area weights of liquid isocyanate when it is impregnated in each of the two glass fiber pads 42, 43. In other words, the unit area weight of isocyanate impregnated in the resin-impregnated semi-rigid foamed urethane layer 41 can be significantly increased compared to the sum of the unit area weights of isocyanate that can be impregnated in each of the two glass fiber pads 42, 43.

[0159] Accordingly, compared to a core component comprising two resin-impregnated glass fiber pads (each impregnated with liquid isocyanate and hardened) and a semi-rigid foamed urethane layer 41a, the core component 40a exhibits significantly higher rigidity. Therefore, the panel-type sunshade 40 including the core component 40a can maintain its original panel shape well. Consequently, compared to conventional sunshade devices, the sunshade device SD slides more smoothly along the two guide rails 30 in the forward and backward directions.

[0160] As explained above, in this first embodiment, the core component 40a of the sunshade 40 is composed of a laminate including a glass fiber pad 42 on the outer skin side, a resin-impregnated semi-rigid foamed urethane layer 41, and a glass fiber pad 43 on the inner skin side, as described above.

[0161] In the laminate, the resin-impregnated semi-rigid foamed urethane layer 41 does not require curing for impregnation as the two glass fiber pads 42, 43 containing glass fibers that are difficult to impregnate with liquid isocyanate. Instead, it is formed by uniformly impregnating the semi-rigid foamed urethane layer 41a with liquid isocyanate and allowing it to harden.

[0162] Incidentally, when testing the bending strength of the sunshade 40 formed in the above manner, an implementation sample of the sunshade 40 is prepared, and the bending strength of the implementation sample is tested using a bending strength testing device.

[0163] The prototype is formed from a flat central portion 40d, which is equivalent to a sunshade 40. The prototype is formed, for example, into a flat plate shape with a width of 50 mm, a length of 150 mm, and a total thickness of 7.0 mm.

[0164] In addition, the liquid isocyanate impregnated in the semi-rigid foamed urethane layer of the test sample has a unit area weight of 200 g / m². 2 The unit area weight of the glass fiber pads on the outer skin layer and the inner skin layer of the test sample is 300 g / m². 2 .

[0165] In addition, during the bending strength test, a specimen with the same structure as the flat central portion of a conventional sunshade was prepared as a comparison specimen. The conventional sunshade has an outer skin member 40b and an inner skin member 40c of the sunshade 40, and has a core member different from the core member 40a of the sunshade 40.

[0166] The core component of the conventional sunshade is composed of a resin-impregnated glass fiber pad 42 on the outer skin side, a resin-impregnated semi-rigid foamed urethane layer 41a and a resin-impregnated glass fiber pad 43 on the inner skin side, which correspond to the outer skin side glass fiber pad 42, the resin-impregnated semi-rigid foamed urethane layer 41 and the inner skin side glass fiber pad 43 of the sunshade 40.

[0167] Here, the outer layer resin-impregnated fiberglass pad and the inner layer resin-impregnated fiberglass pad are formed by impregnating the outer layer resin-impregnated fiberglass pad 42 and the inner layer resin-impregnated fiberglass pad 43 of the sunshade 40 with liquid isocyanate and then hardening them. Furthermore, the weight per unit area of ​​the liquid isocyanate relative to each of the outer layer resin-impregnated fiberglass pad and the inner layer resin-impregnated fiberglass pad is 50 g / m². 2 ±5g / m 2 Values ​​within (e.g., 30g / m³) 2 In addition, the comparative specimen, like the implementation specimen, is formed into a flat plate shape with a width of 50 mm, a length of 150 mm, and a total thickness of 7.0 mm.

[0168] In addition, such as Figure 12 As shown, the bending strength testing device has two support elements 80a and 80b and a load element 80c. Figure 19 As shown, two fulcrum elements 80a and 80b are arranged at a distance in the horizontal direction, and the horizontal distance between each fulcrum 81 and 82 of the two fulcrum elements 80a and 80b is set to 100mm.

[0169] Furthermore, the load member 80c is supported vertically in the middle between the two fulcrum elements 80a and 80b, with its lower end 83 facing the midpoint between the fulcrums 81 and 82 of the two fulcrum elements 80a and 80b. Additionally, the horizontal distance between each of the two fulcrums 81 and 82 and the lower end 83 of the load member 80c is 50 mm (refer to...). Figure 12 ).

[0170] When performing a bending strength test on a specimen T using a bending strength testing apparatus configured as shown, such as Figure 12 As shown, the sample T is placed on each of the fulcrums 81 and 82 in a manner that spans the two fulcrum elements 80a and 80b.

[0171] In this placement state, when the load member 80c is moved downward toward the midpoint between the two support points 81 and 82, the load member 80c applies a load downward toward the center of the specimen T in the left-right direction at its lower end 83. Therefore, the maximum load relative to the specimen T and the flexural elastic gradient when the maximum load is applied to the specimen T can be determined by the bending strength testing device, and these can be used as the bending strength characteristics of the specimen T.

[0172] Thus, the comparative sample, as the placement sample T, is placed on each of the support points 81 and 82 of the two support elements 80a and 80b in the same manner as described above, and an attempt is made to apply a load to the comparative sample using the load member 80c in the same manner as described above. Accordingly, as Figure 11 The chart shows the bending strength characteristics of the comparative specimen, which has a maximum bending strength of 48 N and a bending elastic gradient of 115 N / cm.

[0173] On the other hand, the experimental specimen, as the placement specimen T, is placed on each of the support points 81 and 82 of the two support elements 80a and 80b in the same manner as described above, and a load is applied to the experimental specimen using the load member 80c in the same manner as described above. Accordingly, as Figure 11 The graph shows the bending strength characteristics of the specimen, which has a maximum bending strength of 70 N and a bending elastic gradient of 220 N / cm.

[0174] Comparing these bending strength characteristics, it can be seen that the maximum load relative to the implemented specimen is approximately 1.5 times that relative to the maximum load of the comparative specimen. Furthermore, it can be seen that, in this case, the bending elastic gradient of the implemented specimen is approximately twice that of the comparative specimen.

[0175] Therefore, it can be seen that the bending strength characteristics of the implemented specimen are significantly improved compared to those of the comparative specimen. In other words, it can be seen that the sunshade 40 manufactured by this first embodiment has very high rigidity compared to conventional sunshades.

[0176] Furthermore, in this first embodiment, by setting the impregnation target of the liquid isocyanate as the semi-rigid foamed urethane layer 41a, the unit area weight of the liquid isocyanate impregnation can be increased to a unit area weight that can further enhance the rigidity of the sunshade 40, for example, 200 g / m², as described above. 2 As a result, as can also be seen from the bending strength test results described above, the rigidity of the core member 40a, and consequently the rigidity of the sunshade 40, can be significantly improved compared to the case where liquid isocyanate is impregnated in the two glass fiber pads 42, 43.

[0177] (Second Implementation)

[0178] Figure 13 The main parts of a second embodiment of the sunshade device of the present invention are shown. In the second embodiment, the sunshade device is the sunshade device SD described in the first embodiment, including... Figure 13 and Figure 14 The sunshade shown (hereinafter also referred to as sunshade 40 in this second embodiment) is used instead of sunshade 40. Furthermore, the sunshade device described in this second embodiment is also represented by the symbol SD, just like the sunshade device SD described in the first embodiment.

[0179] The sunshade 40 described in this second embodiment includes the outer skin component 40b and the inner skin component 40c described in the first embodiment, and includes a core component 40m to replace the core component 40a (see reference). Figure 13 and Figure 14 The core component 40m is stacked between the outer skin component 40b and the inner skin component 40c.

[0180] The core component 40m includes the resin-impregnated semi-rigid foamed urethane layer 41 described in the first embodiment, and includes a skin-side resin-impregnated glass fiber pad 48 and an inner skin-side resin-impregnated glass fiber pad 49, respectively replacing the skin-side glass fiber pad 42 and the inner skin-side glass fiber pad 43 described in the first embodiment. In this second embodiment, the resin-impregnated semi-rigid foamed urethane layer 41 is laminated between the skin-side resin-impregnated glass fiber pad 48 and the inner skin-side resin-impregnated glass fiber pad 49 (see reference). Figure 14 ).

[0181] The outer skin layer resin-impregnated glass fiber pad 48 is formed by uniformly impregnating the entire outer skin layer side glass fiber pad 42 described in the first embodiment with liquid isocyanate and then hardening it. On the other hand, the inner skin layer resin-impregnated glass fiber pad 49 is formed by uniformly impregnating the entire inner skin layer side glass fiber pad 43 described in the first embodiment with liquid isocyanate and then hardening it.

[0182] In this second embodiment, the weight per unit area of ​​the liquid isocyanate impregnated in the glass fiber pad 42 on the skin side, in order to form the resin-impregnated glass fiber pad 48 on the skin side, is set to a value within a specified weight per unit area range, for example, 30 g / m². 2 On the other hand, the unit area weight of the liquid isocyanate impregnated in the glass fiber pad 43 on the inner skin side, in order to form the resin-impregnated glass fiber pad 49 on the inner skin side, is also set to a value within the specified unit area weight range, for example, 30 g / m². 2Consequently, the total weight per unit area and total thickness of the sunshade 40 in this second embodiment are, for example, 1290 g / m². 2 and 7.0mm.

[0183] In this second embodiment, the range of unit area weight of the liquid isocyanate impregnated in the epidermal layer-side resin-impregnated glass fiber pad 42 and the lining layer-side resin-impregnated glass fiber pad 43, which are used to form the epidermal layer-side resin-impregnated glass fiber pad 48 and the lining layer-side resin-impregnated glass fiber pad 49, i.e., the specified unit area weight range, is set to 20 g / m². 2 ~50g / m 2 .

[0184] Within the specified range of weight per unit area, the lower limit is set at 20 g / m². 2 The reason is: if it is less than 20g / m 2 This would result in insufficient rigidity of the resin-impregnated glass fiber mat. On the other hand, setting the upper limit to 50 g / m 2 The reason is that if it exceeds the stated 50g / m 2 Therefore, structurally speaking, glass fiber mats are difficult to impregnate. Furthermore, the weight per unit area of ​​the liquid isocyanate impregnated in the epidermal glass fiber mat 42 and the lining glass fiber mat 43 can also be 30 g / m². 2 ±3g / m 2 Values ​​within the range, such as 30g / m 2 .

[0185] Thus, in the sunshade 40 described in this second embodiment, the core member 40m constructed in the manner described above... Figure 14 As shown, it is layered between the outer skin member 40b and the inner skin member 40c. Based on this layering, the sunshade 40 is compressed and shaped to have the following characteristics: Figure 13 The cross-sectional shape is shown in the figure. The other structures of the sunshade device described in this second embodiment are the same as those in the first embodiment.

[0186] In the sunshade 40 constructed in the above manner according to the second embodiment, unlike the two glass fiber pads 42 and 43 of the core member 40a described in the first embodiment, the core member 40m uses two resin-impregnated glass fiber pads 48 and 49. Moreover, the core member 40m is formed by laminating a resin-impregnated semi-rigid foamed urethane layer 41 described in the first embodiment between the two resin-impregnated glass fiber pads 48 and 49.

[0187] Therefore, the core component 40m in this second embodiment has a total rigidity that is additional to the rigidity of the resin-impregnated semi-rigid foamed urethane layer 41 described in the first embodiment, plus the rigidity of two resin-impregnated glass fiber pads 48 and 49.

[0188] As a result, the sunshade 40 in this second embodiment, based on the total rigidity of the core member 40m, can be further strengthened compared to the sunshade 40 in the first embodiment. This means that the original plate shape of the sunshade 40 in this second embodiment (refer to...) Figure 13 Compared to the sunshade 40 of the first embodiment, it can be maintained better. Other effects in this second embodiment are the same as those in the first embodiment.

[0189] (Third Implementation)

[0190] Figure 15 A third embodiment of the automotive sunshade device of the present invention is shown. The sunshade device in the third embodiment has the following structure: in the plate-type sunshade 40 of the sunshade device SD described in the first embodiment, a front end portion 40e, a left edge portion 40g, and a right edge portion 40h are included instead of the front end portion 40e, the left edge portion 40g, and the right edge portion 40h. Furthermore, the sunshade device of this third embodiment is also represented by the symbol SD, just like the sunshade device SD of the first embodiment.

[0191] Furthermore, the sunshade device SD described in the third embodiment has the following structure: in the sunshade device SD described in the first embodiment, a left rear sliding member 70 and a right rear sliding member 70 are included instead of the left rear sliding member 60 and the right rear sliding member 60. Moreover, in this third embodiment, the left front sliding member 60 and the right front sliding member 60 described in the first embodiment are not used.

[0192] First, the structure of the front end portion 40i of the panel-type sunshade 40 in this third embodiment will be described. For example... Figures 15-17 As shown in any of them, when the front end portion 40i is compressed and formed at a compression rate higher than that of the flat central portion 40d as described in the first embodiment, it is heated and compressed together with the compression forming to protrude from the front end portion of the flat central portion 40d in a curved shape that convexes slowly toward its front, while bending toward the inner skin member 40c.

[0193] Next, the structures of the left and right side edges 40j and 40k of the plate-shaped sunshade 40 in this third embodiment will be described. The left edge 40j, in the left and right side edges 40j and 40k, is formed similarly to the left edge 40g described in the first embodiment, extending to the left from the left side of the flat central portion 40d (see reference). Figure 15 ).also, Figure 15 The diagram shows the sunshade 40 as viewed from the rear (side of the roof of the vehicle).

[0194] The left edge 40j is compressed at its middle length portion j1 ​​and rear length portion j2 with the same compression ratio as the left edge 40g described in the first embodiment (see reference). Figure 17 Furthermore, the left edge portion 40j's front section j3 in the length direction is compressed and formed into a left support portion (hereinafter also referred to as the left support portion j3) at a compression rate lower than that of the middle section j1 ​​and the rear section j2 in the length direction, for example, at the same compression rate as the flat central section 40d (see reference). Figure 15 and Figure 17 ).

[0195] This means that the shape of the left support portion j3 is more bulging (expanded shape) than the shapes of the middle portion j1 ​​and the rear portion j2 in the length direction. The left support portion j3 serves as a substitute for the left front sliding member 60 described in the first embodiment.

[0196] Here, as Figure 18 As shown, the left support portion j3 is positioned offset further downwards (towards the skin member 40b) than the flat central portion 40d. Accompanyingly, the left support portion j3, on its skin member 40b side, is located at the middle portion j1 ​​of the left edge 40j in the longitudinal direction. Figure 18 On the lower side of the diagram, the left support portion j3 is located at the middle part j1 of the left edge portion 40j along its length direction, on the side of its inner skin member 40c. Figure 18 The upper side of the diagram. Furthermore, at the rear portion j2 in the length direction, a cut is made to form a cut portion j4 identical to the cut portion j described in the first embodiment (see reference). Figure 15 , Figure 17 ).

[0197] On the other hand, the right edge portion 40k is compressed at its mid-length portion k1 and rear-length portion k2 with the same compression ratio as the right edge portion 40h described in the first embodiment. Furthermore, the front-length portion k3 of the right edge portion 40k is compressed into a right-side support portion (hereinafter also referred to as right-side support portion k3) with a compression ratio lower than that of the mid-length portion k1 and the rear-length portion k2, for example, the same compression ratio as that of the flat central portion 40d. This means that the shape of the right-side support portion k3 is more bulging (expanded shape) than the shapes of the mid-length portion k1 and the rear-length portion k2. The right-side support portion k3 serves as a substitute for the right front sliding member 60 described in the first embodiment.

[0198] Here, the right support portion k3, like the left support portion j3, is positioned further downward than the flat central portion 40d. Simultaneously, the right support portion k3, at its skin member 40b side, is located below the middle portion k1 in the length direction of the right edge 40k, similar to the skin member 40b side of the left support portion j3. On the other hand, the right support portion k3, at its inner skin member 40c side, is located above the middle portion k1 in the length direction of the right edge 40k, similar to the inner skin member 40c side of the left support portion j3. Furthermore, a cut portion k4, identical to the cut portion j described in the first embodiment, is formed by cutting away the rear portion k2 in the length direction (see...). Figure 15 ).

[0199] Next, the structures of the left rear sliding member 70 and the right rear sliding member 70 in this third embodiment will be described. In the left rear sliding member 70 and the right rear sliding member 70, the left rear sliding member 70 is installed at the cutout j4 formed at the rear portion j2 of the left side edge 40j of the sunshade 40 (see reference). Figure 19 On the other hand, the right rear sliding member 70 is installed at the cutout k4 formed at the rear part k2 of the right edge 40k of the sunshade 40 (see reference). Figure 15 ).

[0200] Both the left rear sliding member 70 and the right rear sliding member 70 have the same structure; therefore, the structure of the left rear sliding member 70 will be described below as an example. Figure 19 and Figure 20 As shown, the left rear sliding member 70 includes a member body 70a and a mounting plate 70b. The member body 70a has a base plate portion 71, which clamps the rear portion j2 of the left edge portion 40j in the longitudinal direction (see reference) between the base plate portion 71 and the mounting plate 70b. Figure 20 ).

[0201] The clamping is performed in the following manner. Specifically, the base plate portion 71 has a pair of fork-shaped portions 71a (in Figure 20 Only one fork-shaped portion 71a is shown in the image. A pair of through holes j5 are fitted into the rear portion j2 in the longitudinal direction. Figure 20 Only one through hole, j5, is shown in the image. (Refer to...) Figure 15 Furthermore, a pair of fork-shaped portions 71a and a pair of through holes j5 in the rear portion j2 along the length direction are formed protruding from the base plate portion 71 toward the mounting plate 70b side.

[0202] On the other hand, the mounting plate 70b has a pair of protrusions 72 (in Figure 20 Only one of the protrusions 72 is shown, where the interior of a pair of through holes j5 in the rear portion j2 along the longitudinal direction engages with a pair of fork-shaped portions 71a in the base plate portion 71. This provides the clamping effect. Furthermore, the pair of protrusions 72 are formed from the mounting plate 70b toward the base plate portion 71, facing the pair of through holes j5 in the rear portion j2 along the longitudinal direction.

[0203] In addition, such as Figure 19 and Figure 20 As shown in any of them, the main body 70a of the component includes an elongated shell portion 73, a pair of sliding plates 74, a spring plate 75, and a pair of elastic plates 76. Figure 20 As shown, the elongated shell portion 73 is integrally formed with the base plate portion 71 at its bottom wall portion 73a, and the elongated shell portion 73 at its L-shaped wall portion 73b, as... Figure 20 As shown, it engages with the left end of the mounting plate 70b, thereby maintaining the clamping action between the base plate portion 71 and the mounting plate 70b.

[0204] like Figure 19 As shown, a pair of sliding pieces 74 are housed within the housing portion 73 via a spring plate 75, and the pair of sliding pieces 74 are forced by the spring plate 75 toward the upper wall portion 31 of the guide rail 30. Thus, the pair of sliding pieces 74 slide against the inner surface of the upper wall portion 31 of the guide rail 30.

[0205] Here, a spring plate 75 is installed between the lower wall portion (hereinafter referred to as the lower wall portion 32) of the guide rail 30 and a pair of sliding plates 74, the spring plate 75 applying force to the pair of sliding plates 74 toward the upper wall portion 31 of the guide rail 30. At the bottom wall portion 33 of the guide rail 30 (see reference...) Figure 20 On the outer surface of the housing portion 73, a pair of elastic tabs 76 are provided at intervals along the length direction. Thus, the pair of elastic tabs 76 elastically abut against the inner surface of the bottom wall portion 33 of the guide rail 30. Furthermore, the right rear sliding member 70 is also constructed from the same components as the left rear sliding member 70.

[0206] As described above, let's assume that the left and right support parts j3 and k3 (refer to...) Figure 15 ) and left and right rear sliding components 70 (refer to Figure 15 It is provided in the sunshade 40. Here, in the left edge 40j of the sunshade 40, its front part j3 in the longitudinal direction, that is, the left support part j3, is compressed at a lower compression rate than the compression rates of the central part j1 and the rear part j2 in the longitudinal direction of the left edge 40j of the sunshade 40, so that it has a more expanded shape (expanded shape) than the shape of the central part j1 and the rear part j2 in the longitudinal direction.

[0207] Furthermore, in the sunshade 40, the front part k3 of its right edge 40k in the longitudinal direction, i.e. the right support part k3, is compressed at a lower compression ratio than the compression ratios of the central part k1 and the rear part k2 in the longitudinal direction of the right edge 40k of the sunshade 40, thereby having a more expanded shape (expanded shape) than the shapes of the central part k1 and the rear part k2 in the longitudinal direction.

[0208] In addition, the left rear sliding member 70 slides against the lower wall 32 and upper wall 31 of the left guide rail 30 at the bottom wall 73a of its housing 73 and a pair of sliding plates 74 under the force applied by the spring plate 75.

[0209] According to the above structure, the left edge 40j of the sunshade 40 can bulge its central part j1 and rear part j2 in the length direction from the inner surfaces of the upper wall 31 and lower wall 32 of the left guide rail 30, and the right edge 40k of the sunshade 40 can bulge its central part k1 and rear part k2 in the length direction from the inner surfaces of the upper wall 31 and lower wall 32 of the right guide rail 30.

[0210] As a result, the left and right side edges 40j and 40k of the sunshade 40 are slidably connected to the left and right side guide rails 30 together with the left and right rear sliding members 70 only through the left and right side support portions j3 and k3. Therefore, during the opening and closing operation of the sunshade device SD, the sunshade device SD can always be opened / closed with sliding resistance that allows for smooth opening and closing operations. The other structures of the sunshade device SD in this third embodiment are the same as those in the first embodiment.

[0211] As explained above, in this third embodiment, in the panel-type sunshade 40, its front end portion 40i, as described above, is compressed and formed at a compression rate higher than that of the flat central portion 40d as described in the first embodiment. It is then heated and compressed together with this compression forming to protrude from the front end portion of the flat central portion 40d in a gently convex curved shape towards its front, while simultaneously bending towards the inner skin member 40c. At this time, the front end portion 40e is fused from the outer skin member 40b side to the inner skin member 40c side through heating and compression during the heating and compression forming process.

[0212] Therefore, in the front end portion 40i of the sunshade 40, the core member 40a is not exposed from the skin member 40b. Thus, even when observing the sunshade 40 from its skin layer 45 side, the end face of the core member 40a is not visible, ensuring the aesthetic appearance of the front end portion 40i of the sunshade 40.

[0213] Furthermore, as described above, the front end portion 40i of the sunshade 40 is heated and compressed to protrude from the front end portion of the flat central portion 40d in a gently convex curved shape towards its front, while simultaneously curving towards the inner skin member 40c. Moreover, in the core member 40a, the resin-impregnated semi-rigid foamed urethane layer 41, which is stacked between the two glass fiber pads 42 and 43 on both sides, is formed, as described in the first embodiment, by impregnating the entire semi-rigid foamed urethane layer 41a with liquid isocyanate during the heated and compressed molding process and hardening the liquid isocyanate.

[0214] Here, regarding the structure of the semi-rigid foamed urethane layer 41a, the weight per unit area of ​​the liquid isocyanate impregnated in the semi-rigid foamed urethane layer 41a, as described in the first embodiment, is significantly increased compared to the weight per unit area of ​​the liquid isocyanate impregnated in the glass fiber pads 42 and 43 on both sides. Therefore, the rigidity of the front end 40i of the sunshade 40 is further improved.

[0215] Therefore, during the opening and closing of the sunshade 40, even if the operator presses the front end 40i with their hand, the front end 40i will not deform at all and can reliably maintain its original shape. Other effects are the same as in the first embodiment.

[0216] Furthermore, when implementing this invention, it is not limited to the various embodiments described above, but various modifications can be listed below.

[0217] (1) When implementing the present invention, the third embodiment may also be modified in the way described in the second embodiment of the sunshade device SD instead of the sunshade device SD described in the first embodiment.

[0218] In this case, the core component 40m comprises not only a resin-impregnated semi-rigid foamed urethane layer 41, but also two resin-impregnated glass fiber pads 48 and 49. Therefore, the rigidity of the core component 40m can be further improved compared to the third embodiment described above.

[0219] Consequently, the rigidity of the front end 40i of the sunshade 40 can also be further improved. As a result, the effect of the third embodiment can be further improved by further increasing the rigidity.

[0220] (2) When implementing the present invention, the resin impregnated in the resin impregnated semi-rigid foamed urethane layer described in the first or second embodiment is not limited to liquid isocyanate, but can be any thermosetting resin such as urethane.

[0221] (3) When implementing the present invention, the resin impregnated in the resin impregnated glass fiber pad described in the second embodiment is not limited to liquid isocyanate, but can be any thermosetting resin such as urethane.

[0222] (4) In implementing the present invention, the skin member 40b described in the first embodiment may be replaced by an adhesive layer such as a simple adhesive film on the skin layer 45 instead of the barrier film 44. In addition, the inner skin member 40c described in the first embodiment may also have an adhesive layer on the inner skin layer 47, and is not limited to the adhesive film 46.

Claims

1. A panel-type sunshade, comprising an outer skin component, an inner skin component, and a core component stacked between the outer skin component and the inner skin component. The core component includes two resin-impregnated glass fiber pads and a resin-impregnated semi-rigid foamed urethane layer laminated between the two resin-impregnated glass fiber pads. The two resin-impregnated glass fiber mats are formed by impregnating the corresponding glass fiber mats with liquid thermosetting resin and then curing the liquid thermosetting resin. The resin-impregnated semi-rigid foamed urethane layer is formed by impregnating the semi-rigid foamed urethane layer entirely with liquid thermosetting resin and then curing the liquid thermosetting resin. In the two resin-impregnated glass fiber mats, the liquid thermosetting resin impregnated in the impregnated glass fiber mats has a first specified weight per unit area of ​​20 g / m². 2 ~50 g / m 2 Weight per unit area In the resin-impregnated semi-rigid foamed urethane layer, the liquid thermosetting resin impregnated in the semi-rigid foamed urethane layer has a second specified unit area weight range of 100 g / m². 2 ~500 g / m 2 Weight per unit area.

2. The panel-type sunshade according to claim 1, characterized in that, The skin component includes a skin layer and a skin layer side adhesive layer. The lining component includes an lining layer and a side bonding layer for the lining layer. In the core component, one of the two resin-impregnated glass fiber pads is bonded to the skin layer via the skin layer side adhesive layer, with the skin layer side adhesive layer facing the skin layer in a manner that separates the two pads. On the other hand, the other resin-impregnated glass fiber pad is bonded to the inner skin layer via the inner skin layer side adhesive layer, with the inner skin layer side adhesive layer facing the inner skin layer in a manner that separates the two pads.

3. The panel-type sunshade according to claim 1, characterized in that, The unit area weight of the liquid thermosetting resin impregnated in each of the glass fiber pads is 30 g / m². 2 ±3 g / m 2 , The weight per unit area of ​​the liquid thermosetting resin impregnated in the semi-rigid foamed urethane layer is 200 g / m². 2 ±20 g / m 2 .

4. The panel-type sunshade according to claim 1, characterized in that, The liquid thermosetting resin is a liquid isocyanate.

5. A sunshade device for automobiles, which is applied to a window formed in a sunroof of an automobile via two guide rails for opening and closing. The automotive sunshade device includes a panel-type sunshade and multiple sliding components. The panel-type sunshade includes an outer skin component, an inner skin component, and a core component stacked between the outer skin component and the inner skin component. The core component includes two resin-impregnated glass fiber pads and a resin-impregnated semi-rigid foamed urethane layer laminated between the two resin-impregnated glass fiber pads. The two resin-impregnated glass fiber mats are formed by impregnating the corresponding glass fiber mats with liquid thermosetting resin and then curing the liquid thermosetting resin. The resin-impregnated semi-rigid foamed urethane layer is formed by impregnating the semi-rigid foamed urethane layer entirely with liquid thermosetting resin and then curing the liquid thermosetting resin. In the two resin-impregnated glass fiber mats, the liquid thermosetting resin impregnated in the impregnated glass fiber mats has a first specified weight per unit area of ​​20 g / m². 2 ~50 g / m 2 Weight per unit area In the resin-impregnated semi-rigid foamed urethane layer, the liquid thermosetting resin impregnated in the semi-rigid foamed urethane layer has a second specified unit area weight range of 100 g / m². 2 ~500 g / m 2 Weight per unit area The plurality of sliding components are installed on at least the rear portions of the left and right side edges of the panel-shaped sunshade.

6. The automotive sunshade device according to claim 5, characterized in that, The panel-type sunshade includes: The structure comprises the outer skin member, the inner skin member, and the core member stacked between the outer skin member and the inner skin member, and is formed to have a flat central portion; front and rear end portions extending from the flat central portion to the front and rear sides; and left and right side edges extending from the flat central portion to the left and right sides. The left and right side edges include their respective front portions and all other portions besides the aforementioned front portions. Each of the remaining portions is formed with a compression rate higher than that of the central portion of the flat plate, while each of the front portions is formed with a compression rate lower than that of the remaining portions. The rear end is formed with a compression rate higher than that of the flat central portion. The front end is compressed at a higher compression rate than the flat central portion, and is formed into a curved shape that gently bulges forward towards the inner skin member.

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