Lining for molded ceiling for vehicle, and molded ceiling for vehicle

Abstract

The invention provides a lining material for a molded ceiling for a vehicle and the molded ceiling for the vehicle, which can inhibit peeling or cracking of a heat insulation layer and obtain a stable heat insulation effect. The liner for the molded ceiling for the vehicle is arranged between a base material of the molded ceiling for the vehicle and a vehicle body panel. The interlining has: a fiber layer which is a sheet-like non-woven fabric facing the vehicle body panel side; and a heat-insulating film layer which is composed of a metal film integrated with one surface of the fiber layer and reflects radiant heat from the vehicle body panel side. Further, the liner has a barrier layer, is laminated on the base material side of the fiber layer via an adhesive resin, and blocks or suppresses gas flow between the liner and the base material. The non-woven fabric has high tensile strength and low stretchability, so that the extension of the lining material during the molding of the molded ceiling for the vehicle can be suppressed. Furthermore, since the heat-insulating film layer and the fiber layer are integrally deformed, the elongation of the fiber layer and the heat-insulating film layer is less likely to be varied even at a position where the shape of the molded ceiling for a vehicle changes.

Description

Technical Field

[0001] The present invention relates to a lining material for a vehicle formed roof and the vehicle formed roof. Background Art

[0002] Various materials have been known for use as molded ceiling materials for vehicles. For example, during the hottest summer months, the interior of a car can become extremely hot, so in recent years, molded ceiling materials with heat-insulating and heat-isolating properties have been developed. The roof panels of a vehicle body are large in area, and the radiant heat from sunlight hitting them significantly increases the temperature inside the vehicle cabin. Furthermore, as the temperature inside the vehicle cabin rises, the energy load associated with using air conditioning also increases. Therefore, as a means of suppressing the temperature rise inside the vehicle cabin, molded ceiling materials with heat-insulating properties are being used.

[0003] For example, Patent Document 1 discloses a far-infrared reflective film used as a lining for a vehicle ceiling material. This far-infrared reflective film reflects radiant heat from the ceiling panel, thereby reducing the amount of heat that enters the vehicle cabin. Furthermore, Patent Document 2 discloses a vehicle ceiling material including an infrared reflective layer as a lining. Furthermore, as an example of an infrared reflective layer, an aluminum-deposited film is disclosed, comprising a base film with an aluminum-deposited layer formed on its surface.

[0004] Prior art literature Patent Literature Patent Document 1: Japanese Patent Application Publication No. 2019-117228 Patent Document 2: Japanese Patent Application Laid-Open No. 2013-129308 Summary of the Invention Problems to be solved by the invention However, the aluminum-deposited films previously used as linings for vehicle ceiling materials often consist of a base film made of a resin film such as polyethylene terephthalate or polypropylene, with aluminum deposited on the surface to form the thermal insulation layer. However, these base films have the characteristic of stretching well when stretched. When molding the vehicle ceiling material, if the base film is stretched beyond the expected length, there is a tendency for the elongation of the stretched thermal insulation layer to differ from that of the base film. Consequently, excessive pressure applied to areas of the molded vehicle ceiling material, such as inflection points, where there are significant fluctuations or shape changes, can cause scaling or cracking of the thermal insulation layer, partially reducing the thermal insulation performance of the vehicle ceiling material.

[0005] The present invention has been made in view of this point, and an object thereof is to provide a lining for a vehicle molded ceiling and a vehicle molded ceiling that can suppress peeling or cracking of a heat insulating layer and obtain a stable heat insulating effect.

[0006] Means used to solve problems A feature of a lining material for a molded vehicle ceiling that addresses the aforementioned issues is that the lining material is disposed between a substrate of the molded vehicle ceiling and a vehicle body panel, and comprises: a fiber layer comprising a sheet of nonwoven fabric facing the vehicle body panel; a heat-insulating film layer comprising a metal film integrated with one surface of the fiber layer and reflecting radiant heat from the vehicle body panel; and a barrier layer laminated on the substrate side of the fiber layer via an adhesive resin and functioning to block or inhibit gas flow between the fiber layer and the substrate.

[0007] One feature and advantage of the above structure is that the lining has a fiber layer facing the vehicle body panel and a barrier layer laminated on the inner side of the fiber layer via an adhesive resin. The fiber layer is a sheet of non-woven fabric, and a thermal insulation film layer is formed on one surface thereof in an integrated manner with the fiber layer. Since the non-woven fabric constituting the fiber layer has a high tensile strength and lower elasticity than a resin film, the elongation of the lining during the molding of the vehicle molded ceiling can be suppressed. In addition, since the thermal insulation film layer deforms integrally with the fiber layer, it is difficult for a difference in the elongation of the fiber layer and the thermal insulation film layer to occur even in areas with large undulations or changes in shape. In other words, the thermal insulation film layer can be suppressed from being overstretched, and peeling or cracking of the thermal insulation film layer can be prevented. Therefore, the lining having this structure can achieve a stable thermal insulation effect for the vehicle molded ceiling.

[0008] The lining material for the molded vehicle ceiling may also be configured such that the fiber layer is a spunbonded nonwoven fabric or a spunlace nonwoven fabric.

[0009] One feature and advantage of the above structure is the use of spunbond or spunlace nonwoven fabrics as the fiber layer. These nonwoven fabrics have excellent surface smoothness, making them easy to process for thermal insulation, such as vapor deposition or printing. Therefore, they are suitable as the fiber layer that integrates the thermal insulation film layer.

[0010] In the above-mentioned lining material for the molded vehicle ceiling, the heat-insulating film layer may be formed of an aluminum vapor-deposited film.

[0011] A key feature and advantage of the above structure is that aluminum is vapor-deposited on one surface of the fiber layer. Because aluminum has a high reflectivity for infrared radiation, using an aluminum vapor-deposited film as the thermal insulation film enhances thermal insulation. Furthermore, vapor deposition allows for easier control of film thickness, allowing for thinner film formation. This allows for the thermal insulation film to be formed to suit the specifications of the vehicle molded ceiling.

[0012] The lining material for the vehicle molded ceiling may be configured such that the heat-insulating film layer is formed on the surface of the fiber layer on the vehicle body panel side, and the lining material includes a protective layer laminated on the heat-insulating film layer on the vehicle body panel side.

[0013] One feature and advantage of the above structure is that the thermal insulation film layer faces the vehicle body panel. This improves the efficiency of reflecting radiant heat from the vehicle body panel, thereby enhancing the thermal insulation effect. Furthermore, the protective layer prevents the aluminum particles that make up the thermal insulation film layer from falling off.

[0014] A molded ceiling for a vehicle that solves the above-mentioned problems is a molded ceiling including the above-mentioned lining.

[0015] A characteristic and advantage of this structure is that, during press-forming of the vehicle roof, even in areas with significant undulations or shape changes, the elongation difference between the fiber layer and the thermal insulation film layer is minimized, preventing peeling or cracking of the thermal insulation film layer. This allows for the provision of a vehicle roof with stable thermal insulation.

[0016] Effects of the Invention The present invention, by adopting the above-mentioned structure, can provide a lining for a vehicle molded ceiling and a vehicle molded ceiling that can suppress peeling or cracking of a heat insulating layer and obtain a stable heat insulating effect. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 This is a diagram schematically showing a molded ceiling mounted on a vehicle.

[0018] Figure 2 It is a diagram schematically showing a cross-sectional structure of a molded ceiling for a vehicle according to an embodiment.

[0019] Figure 3 It is a diagram schematically showing a cross-sectional structure of a lining according to an embodiment.

[0020] Figure 4 It is a diagram schematically showing a cross-sectional structure of a lining according to another embodiment.

[0021] Figure 5 This is a diagram showing a state in which a tensile force is applied to the lining of the example.

[0022] Figure 6 It is a figure which shows the state which applied the tensile force to the lining material of a comparative example.

[0023] Description of Reference Numerals 2: Base material layer (base material), 3: Lining, 4: Surface material, 6: Core material, 7: The first fiber reinforced layer, 8: Second fiber reinforced layer, 10: Molded roof for vehicles, 12: Fiber layer, 13: Thermal insulation film layer, 15: Adhesive resin layer (adhesive resin), 16: Barrier layer, 18: Protective layer. DETAILED DESCRIPTION

[0024] Hereinafter, embodiments of the present invention will be described using the accompanying drawings. A vehicle includes a roof panel P (vehicle body panel) made of a steel plate as a roof. Figure 1 The vehicle molded roof 10 of this embodiment is a roof interior material installed on the interior side of the vehicle cabin of the roof panel P. Figure 2 As shown, in the vehicle molded ceiling 10, a laminate including a base material layer 2 (base material), a lining material 3, and a skin material 4 is heated and pressurized by, for example, hot pressing. Figures 2 to 4 The cross-sectional schematic diagram is illustrated with the upper side on the paper as the ceiling panel P side and the lower side as the inner side of the vehicle compartment.

[0025] The lining material 3 is arranged on the ceiling plate P side of the base material layer 2. Figure 3 As shown, the lining material 3 includes a fiber layer 12 and a barrier layer 16 laminated on the surface of the fiber layer 12 facing the base material layer 2 (the vehicle interior). The fiber layer 12 and the barrier layer 16 are bonded to each other via an adhesive resin layer 15 (adhesive resin). Furthermore, the lining material 3 includes a thermal insulation film layer 13 formed integrally with the fiber layer 12 on one surface of the fiber layer 12.

[0026] The fiber layer 12 is, for example, a spunbond nonwoven fabric or a spunlace nonwoven fabric. Spunbond nonwoven fabric is formed by directly aggregating continuous long fibers obtained by melting and spinning a raw material resin to form a sheet-like fiber web, and then bonding the fiber web in a multi-layer overlapping state by a thermal bonding method (Thermal bond method) using heat pressing. Spunbond nonwoven fabric has high strength against stretching because it uses long fibers. Spunlace nonwoven fabric is formed by, for example, forming a sheet-like fiber web from short fibers by a dry method, and spraying a high-pressure water flow in a columnar shape on the fiber web to intertwine the fibers in the web. Spunlace nonwoven fabric is formed by firmly entangled fibers with each other, and can have high strength. In addition, the surface of spunbond nonwoven fabric or spunlace nonwoven fabric is smooth, and it is easy to implement heat insulation processing based on vapor deposition, printing, etc. described later.

[0027] The main raw material of the nonwoven fabric constituting the fiber layer 12 is, for example, PET (polyester) fiber, PP (polypropylene) fiber, etc. Various synthetic fiber nonwoven fabrics such as polyamide, polyester, and polyacrylonitrile can be used in the fiber layer 12 .

[0028] The heat-insulating film layer 13 is composed of a metal film integrated with one surface of the fiber layer 12, and has the function of reflecting infrared rays. In other words, the heat-insulating film layer 13 has the function of reflecting radiant heat from the ceiling board P. For example, Figure 3 As shown, a thermal insulation film layer 13 is integrally formed on the surface of the fiber layer 12 facing the substrate layer 2. The thermal insulation film layer 13 is composed, for example, of an aluminum vapor-deposited film. The aluminum vapor-deposited film is formed by heating and evaporating aluminum under a high vacuum using an electron beam or high-frequency induction method, thereby depositing fine aluminum particles on one surface of the fiber layer 12.

[0029] The thermal insulation film layer 13 can also be formed by printing instead of vapor deposition. For example, an aluminum film can be formed by gravure printing. In gravure printing involves applying ink mixed with aluminum particles to the cells of a cylindrical gravure plate and transferring the ink to one surface of the fiber layer 12. This forms the aluminum film serving as the thermal insulation film layer 13.

[0030] The barrier layer 16 is a non-breathable film, such as an unstretched polypropylene film. Unstretched polypropylene (CPP) is a non-stretched polypropylene film, exhibiting the property of stretching when stretched. The barrier layer 16 exhibits tensile strength and is resistant to rupture, functioning to block or inhibit gas flow between the barrier layer 16 and the substrate layer 2. The adhesive resin layer 15 is provided to bond the barrier layer 16 to the fiber layer 12 and is, for example, extruded polypropylene.

[0031] like Figure 4 As shown, the lining material 3 may also have a structure in which the thermal insulation film layer 13 is formed on the surface of the fiber layer 12 on the ceiling panel P side. In this structure, a protective layer 18 is laminated on the ceiling panel P side of the thermal insulation film layer 13. The protective layer 18 is provided to prevent the aluminum particles constituting the thermal insulation film layer 13 from falling off, and is formed by laminating, for example, acrylic resin or polyurethane.

[0032] like Figure 2 As shown, the base material layer 2 includes a porous core material 6 and fiber-reinforced layers laminated on both sides of the core material 6, which are cured with a thermosetting adhesive or the like. The core material 6 is provided to maintain the shape and rigidity of the vehicle molded roof 10 and is formed into a surface shape that conforms to the surface of the roof panel P. In this embodiment, the core material 6 is a semi-rigid layer of polyurethane foam made of polyurethane resin foam.

[0033] A first fiber-reinforced layer 7 is laminated on the surface of the core material 6 on the side of the ceiling panel P, and a second fiber-reinforced layer 8 is laminated on the surface on the inside of the vehicle cabin. The first fiber-reinforced layer 7 and the second fiber-reinforced layer 8 are provided to maintain the shape of the vehicle molded ceiling 10 and to ensure rigidity. These fiber-reinforced layers are coated or impregnated with a thermosetting adhesive (thermoplastic resin) on their surfaces and are bonded to both sides of the core material 6. Glass fiber mats can be selected for the first fiber-reinforced layer 7 and the second fiber-reinforced layer 8. The glass fiber mat is formed into a sheet by fixing chopped strands (chopped strands) obtained by cutting glass fibers, which are inorganic fibers, into appropriate lengths with a suitable adhesive. Alternatively, a non-woven fabric can be laminated on the inside of the vehicle cabin to protect the surface of the second fiber-reinforced layer 8. For example, a needle-punched non-woven fabric can be selected as the non-woven fabric.

[0034] These fiber-reinforced layers may also be layers made by bonding uncut glass fibers with an adhesive (continuous strand mats). Alternatively, spunlace, spunbond nonwovens, glass paper, or glass fiber woven fabrics may be used. Furthermore, the basis weight in the embodiments may be selected to suit the required strength and other various conditions.

[0035] The fiber reinforcement materials used for these fiber-reinforced layers can also be appropriately selected from inorganic fibers such as chopped strands or natural fibers such as jute fibers (jute), kenaf (kenaf), ramie, hemp (hemp), sisal, bamboo, etc. as organic fibers, and formed into sheets or mats using adhesives such as acrylic acid or needle processing.

[0036] The thermosetting adhesive is selected from a thermosetting resin composed of an isocyanate resin. Isocyanate is suitable from the perspective of being easily fused with the core material 6 composed of the semi-rigid layer of polyurethane foam. In addition, the thermosetting adhesive is not limited to isocyanate resin and can be appropriately selected. The thermosetting adhesive is applied using a sprayer, a roller coater, etc. As described above, by laminating the fiber-reinforced layer containing the thermosetting resin and the core material 6, the strength of the vehicle molded roof 10 can be improved.

[0037] The surface material 4 is arranged on the inner side of the vehicle compartment of the base material layer 2 as the part that bears the appearance surface of the vehicle molded roof 10. The surface material 4 is selected from a material formed by laminating a surface layer and a polyurethane foam sheet. The surface layer can be applied to various materials such as fabrics, cloth, knitted fabrics, or cloth components such as woven fabrics, non-woven fabrics, raised fabrics, rare wool fabrics, luxury wool fabrics, synthetic leather, artificial leather, and genuine leather. In order to obtain a soft touch on the vehicle molded roof 10, the polyurethane foam sheet is applied as a soft layer composed of polyurethane resin foam and laminated. In addition, a structure without laminating a polyurethane foam sheet is also possible.

[0038] Comparison of Lining Strength The linings of the examples and the linings of the comparative examples were compared in terms of the amount of elongation, peeling, or cracking when a tensile force was applied.

[0039] [Example] A lining material in which an unstretched polypropylene film (barrier layer 16 ) is laminated via resin bonding (adhesive resin layer 15 ) onto a spunbond nonwoven fabric (fiber layer 12 ) as the thermal insulation film layer 13 on which aluminum was vapor-deposited.

[0040] [Comparative Example] Lining made of a conventional aluminum vapor-deposited film.

[0041] Reference Figure 5 , the lining of the embodiment was not confirmed to have peeling or cracking in the thermal insulation film layer 13. In addition, the longitudinal and transverse elongation of the lining of the embodiment was suppressed to about one third compared with the lining of the conventional product. Figure 6 In the case of conventional products, for example, peeling or cracking occurs on the aluminum vapor-deposited film within the range indicated by A.

[0042] <Effects of implementation> The lining material 3 of the molded vehicle ceiling 10 according to the above-described embodiment includes a fiber layer 12 facing the ceiling panel P (vehicle body panel) and a barrier layer 16 laminated on the surface of the fiber layer 12 facing the base material layer 2 (the vehicle interior) via an adhesive resin layer 15 (adhesive resin). The fiber layer 12 is a sheet-like nonwoven fabric, with a thermal insulation film layer 13 integrally formed on one surface. Because the nonwoven fabric constituting the fiber layer 12 has high tensile strength and lower stretchability than resin films, elongation of the lining material 3 during molding of the molded vehicle ceiling 10 is minimized. Furthermore, because the thermal insulation film layer 13 deforms integrally with the fiber layer 12, a difference in elongation between the fiber layer 12 and the thermal insulation film layer 13 is minimized, even in areas with significant undulations or shape changes. This prevents excessive elongation of the thermal insulation film layer 13, preventing peeling or cracking of the thermal insulation film layer 13. Therefore, the lining 3 having this structure allows the vehicle molded ceiling 10 to obtain a stable heat insulating effect.

[0043] In the above-described embodiment, lining material 3 can be made of spunbond nonwoven fabric or spunlace nonwoven fabric as the thermal insulation film layer 13. Spunbond nonwoven fabrics and spunlace nonwoven fabrics have excellent surface smoothness and are easily processed for thermal insulation, such as vapor deposition and printing. Therefore, they are suitable as the fiber layer 12 that integrates the thermal insulation film layer 13.

[0044] In the lining material 3 of the above embodiment, aluminum vapor deposition is applied as the thermal insulation film layer 13. Because aluminum has a high reflectivity for infrared radiation, using an aluminum vapor-deposited film as the thermal insulation film layer 13 can enhance the thermal insulation effect. Furthermore, forming the thermal insulation film layer 13 by vapor deposition makes it easier to control the film thickness, allowing for thinner film formation, for example. Therefore, the thermal insulation film layer 13 can be formed to suit the specifications of the vehicle molded ceiling 10.

[0045] In the lining material 3 of the above-described embodiment, by forming the thermal insulation film layer 13 on the surface of the fiber layer 12 facing the ceiling panel P, the efficiency of reflecting radiant heat from the ceiling panel P can be improved. In other words, the thermal insulation effect can be enhanced. Furthermore, by providing the protective layer 18 on the ceiling panel P side of the thermal insulation film layer 13, the aluminum particles constituting the thermal insulation film layer 13 can be prevented from falling off.

[0046] By using the lining material 3 of the above-described embodiment in the vehicle molded roof 10, even in areas of the vehicle molded roof 10 with significant undulations or shape changes, a difference in elongation between the fiber layer 12 and the thermal insulation film layer 13 is minimized during press molding. This prevents peeling or cracking of the thermal insulation film layer 13. Consequently, a vehicle molded roof 10 with a stable thermal insulation effect can be provided.

[0047] The lining 3 of the above embodiment includes a barrier layer 16 formed of an air-impermeable film on the substrate layer 2 side. This allows the lining 3 to block or suppress the flow of gas between the substrate layer 2 and the lining 3. Specifically, the lining 3 not only has the air-impermeability characteristic of conventional linings, but also has the function of suppressing the expansion of the lining 3 during the molding of the vehicle molded ceiling 10.

[0048] The thermal insulation film layer 13 of the lining 3 of the molded vehicle ceiling 10 of the aforementioned embodiment has the function of reflecting infrared rays. This structure reflects the radiant heat of sunlight S received by the ceiling panel P, preventing the heat from entering the vehicle cabin. Consequently, the temperature rise in the vehicle cabin caused by the radiant heat of sunlight S can be suppressed. Furthermore, energy consumption associated with the use of air conditioning can be reduced.

[0049] The lining material for a vehicle molded ceiling and the vehicle molded ceiling of the present invention are not limited to the appearance and structure described in the above embodiment, and can be implemented in various other forms through various changes, additions, deletions, and structural combinations without changing the scope of the present invention.

[0050] While the substrate layer structure in the above embodiment illustrates a structure in which a polyurethane foam core material and a fiber reinforcement material are laminated, the present invention is not limited thereto and various structures are applicable. For example, a structure in which a nonwoven fabric molded article or a molded nonwoven fabric is laminated on both sides of a core material containing glass fibers and a thermoplastic resin may be used as the substrate layer.

[0051] The heat-insulating film layer of the present invention is not limited to aluminum, and also includes other metal films such as copper that have a heat-insulating effect by reflecting infrared rays.

Claims

1. A lining material for a vehicle molded roof, disposed between a base material of the vehicle molded roof and a vehicle body panel, characterized in that: have: a fiber layer, which is a sheet of non-woven fabric facing the vehicle body panel; a heat-insulating film layer composed of a metal film integrated with one surface of the fiber layer, reflecting radiant heat from the vehicle body panel side; as well as The barrier layer is laminated on the substrate side of the fiber layer via an adhesive resin, and has a function of blocking or inhibiting the flow of gas between the fiber layer and the substrate.

2. The lining material for a vehicle molded ceiling according to claim 1, wherein: The fiber layer is selected from spunbond nonwoven fabric or spunlace nonwoven fabric.

3. The lining material for a vehicle molded ceiling according to claim 2, wherein: The thermal insulation film layer is composed of an aluminum vapor-deposited film.

4. The lining material for a vehicle molded ceiling according to claim 3, wherein: The thermal insulation film layer is formed on the surface of the fiber layer on the vehicle body panel side. The lining has a protective layer laminated on the vehicle body panel side of the thermal barrier film layer.

5. A molded roof for a vehicle, characterized in that: A lining material according to any one of claims 1 to 4.

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