Manufacturing method for formed ceiling

Abstract

To provide a formed ceiling free of defects that might be caused in conventional manufacturing methods depending on materials of formed ceilings.SOLUTION: There is provided a manufacturing method for a formed ceiling in which a glass mat layer and a knit layer for interior finishing are laminated, together with an adhesive and heat-pressed on one of surfaces of a polyurethane-foam layer so as to be formed into the formed ceiling for a vehicle. Therein the glass mat layer is laminated on the polyurethane-foam layer in a state where the adhesive is caused to adhere to a surface overlapping the glass mat layer, of the polyurethane-foam layer.SELECTED DRAWING: Figure 4

Description

[Technical field]

[0001] FIELD OF THE DISCLOSURE The present disclosure relates to a method of manufacturing a molded headliner for a vehicle. [Background technology]

[0002] 2. Description of the Related Art Various molded ceilings have been developed in the past (see, for example, Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2000-272433 (paragraphs

[0019] to

[0022] , etc.) Summary of the Invention [Problem to be solved by the invention]

[0004] Depending on the material of the molded ceiling, conventional manufacturing methods can cause problems. [Means for solving the problem]

[0005] One aspect of the invention is a method for manufacturing a molded ceiling in which a glass mat layer and an interior knit layer are laminated together with an adhesive on one side of a polyurethane foam layer and then hot pressed to form a molded ceiling for a vehicle, in which the glass mat layer is overlapped on the polyurethane foam layer with the adhesive applied to the overlapping surface of the polyurethane foam layer with the glass mat layer. [Brief description of the drawings]

[0006] [Figure 1] FIG. 1 is a side view of a vehicle equipped with a molded headliner. [Diagram 2] Figure 2 shows a cross-section of a molded ceiling [Diagram 3] Figure 3 shows an enlarged cross-section of a molded ceiling. [Figure 4] Figure 4 shows a side view of the laminate line for the molded ceiling. [Diagram 5] FIG. 5 is a cross-sectional view of the laminate before being heat-press molded. [Figure 6] Figure 6 shows a cross-section of a heat-pressed molded ceiling. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0007] [First embodiment] 1 and 2, a molded ceiling 10 according to a first embodiment of the invention is an interior material that is attached to a roof panel 91 of a vehicle 90 by overlapping it from below, and constitutes the ceiling of the passenger compartment of the vehicle 90. Note that a reinforcing board 92 that is bonded to the underside of the roof panel 91 may be provided between the roof panel 91 and the molded ceiling 10, and the molded ceiling 10 is disposed with a gap between it and the reinforcing board 92, for example.

[0008] For example, the molded ceiling 10 is penetrated by components such as an assist grip, a room mirror, and a room light that are attached to the roof panel 91, and is fixed to the roof panel 91 by these components.

[0009] As shown in Figs. 2 and 3, the molded ceiling 10 has a laminated structure in which multiple layers are bonded with an adhesive 30 (see Fig. 3). Specifically, in the laminated structure of the molded ceiling 10, a glass mat layer 22 is bonded to a polyurethane foam layer 21. In this embodiment, a pair of glass mat layers 22 are provided with the polyurethane foam layer 21 in between. In the following, of the pair of glass mat layers 22, the glass mat layer 22 arranged on the passenger compartment side will be referred to as the "first glass mat layer 22A" and the glass mat layer 22 arranged on the roof panel side will be referred to as the "second glass mat layer 22B" as appropriate.

[0010] The polyurethane foam layer 21 may be, for example, made of a rigid polyurethane foam or a semi-rigid polyurethane foam. The polyurethane foam layer 21 may have either an open cell structure or a closed cell structure. In this embodiment, the polyurethane foam layer 21 is the thickest layer among the layers constituting the laminated structure of the molded ceiling 10. From the viewpoint of moldability, the glass mat layer 22 is preferably made of a chopped strand mat.

[0011] In the laminated structure of the molded ceiling 10, a skin layer is laminated on the glass mat layer 22 from the outside (the side opposite to the polyurethane foam layer 21). Specifically, a skin layer laminated on the first glass mat layer 22A is provided as the skin layer, and a knit layer 23 for interior use is provided on this skin layer. In the example of this embodiment, the skin layer on the passenger compartment side is formed of knit, so that the texture of the interior surface of the molded ceiling 10 can be improved. The fiber of the knit layer 23 may be a chemical fiber or a natural fiber. Examples of the chemical fiber include synthetic fibers such as polyester fiber, acrylic fiber, and nylon fiber. Examples of the natural fiber may be animal fibers such as wool, or plant fibers such as cotton and linen. In addition, a skin layer laminated on the second glass mat layer 22B may be provided as the skin layer, and in the example of this embodiment, a skin film 24 (for example, a resin film, etc.) is provided as this skin layer.

[0012] In this embodiment, the knit layer 23 is directly laminated to the first glass mat layer 22A (there is no layer between them other than the adhesive 30). The knit layer 23 has a surface facing the glass mat layer 22A that is preferably brushed. By brushing in this manner, it is possible to increase the adhesiveness of the knit layer 23. In this embodiment, the skin film 24 is also directly laminated to the second glass mat layer 22B.

[0013] The adhesive 30 may be, for example, a liquid thermosetting adhesive (for example, a thermosetting resin adhesive such as a polyurethane adhesive). An example of such an adhesive 30 is one that contains a polyisocyanate compound (so-called liquid isocyanate, etc.). Liquid isocyanate is cured by reacting with water in the presence of heat and a catalyst, and functions as an adhesive. Examples of liquid isocyanate include aromatic TDI (toluene diisocyanate), polymeric MDI (4,4' diphenylmethane diisocyanate), NDI (1,5-naphthalene diisocyanate), TODI (tolidine diisocyanate), PPDI (paraphenylene diisocyanate), XDI (xylylene diisocyanate), TMXDI (tetramethylxylene diisocyanate), and modified products thereof (specifically, those modified in various ways such as urethane modification, allophanate modification, biuret modification, carbodiimide / uretonimine modification, etc.). Among them, preferred are polymeric MDI, modified TDI, modified MDI, or a mixture thereof. As these liquid isocyanates, those with a viscosity of 100 to 10,000 cP at 25°C are more preferred because they have excellent permeability and applicability. Among these, polymeric MDI has a particularly good affinity with glass fibers and is suitable in terms of reactivity, adhesion, and workability. The type of these liquid isocyanates is appropriately selected depending on the adhesion, reactivity, strength of the molded ceiling 10, workability, etc.

[0014] The molded ceiling 10 of this embodiment is formed by laminating a polyurethane foam layer 21, first and second glass mat layers 22A, 22B, a knit layer 23 and a skin film 24 together with an adhesive 30, and molding the laminated ...

[0015] In this embodiment, first, a plurality of layers (in the form of a plate, sheet, or film) constituting the laminated structure of the molded ceiling 10 are prepared. That is, the polyurethane foam layer 21, the first and second glass mat layers 22A, 22B, the knit layer 23, and the skin film 24 are prepared. In this embodiment, the above-mentioned plurality of layers are fed and laminated in the lamination line 50 described below. In this embodiment, the polyurethane foam layer 21 is prepared in the form of a plate cut to an appropriate size in advance, and the first and second glass mat layers 22A, 22B, the knit layer 23, and the skin film 24 are prepared in the form of long strips.

[0016] Next, a lamination process is performed in which the above-mentioned layers are laminated with the adhesive 30. In this lamination process, the first glass mat layer 22A and the second glass mat layer 22B are laminated on the polyurethane foam layer 21 from the front and back. Furthermore, of the three laminated layers, the knit layer 23 is laminated on the first glass mat layer 22A from the outside, and the skin film 24 is laminated on the second glass mat layer 22B from the outside. For example, such lamination of the multiple layers is performed by sandwiching the layers while feeding them downstream with a pair of feed rolls 55. The lamination of the above-mentioned multiple layers may be performed for some of the multiple layers one by one, or may be performed for all the layers at once. In the lamination process of this embodiment, the first glass mat layer 22A and the knit layer 23 are laminated on the polyurethane foam layer 21 from the upper side, but they may be arranged upside down.

[0017] In addition, in this lamination process, the lamination of the above-mentioned multiple layers is performed in a state where an adhesive 30 is applied to at least the overlapping surface of the polyurethane foam layer 21 with the first glass mat layer 22A on which the knit layer 23 is overlapped. Here, the method of applying the adhesive 30 is not limited to application, and may be spraying or immersion. In the example of this embodiment, the adhesive 30 is applied to the overlapping surface of the polyurethane foam layer 21 with the glass mat layer 22 (for example, applied by an application means such as a roll coater) before the glass mat layer 22 is laminated on the polyurethane foam layer 21. Then, with the adhesive 30 applied to the overlapping surface of the polyurethane foam layer 21, the glass mat layer 22 is overlapped on the polyurethane foam layer 21. In the example of this embodiment, the adhesive 30 is applied to both the front and back sides of the polyurethane foam layer 21 (i.e., both overlapping surfaces with a pair of glass mat layers 22).

[0018] In this embodiment, the adhesive 30 is also applied to the first glass mat layer 22A. In this case, the adhesive 30 may be applied to the first glass mat layer 22A from both sides, or only from one side (from the side facing the polyurethane foam layer 21 or the knit layer 23). The adhesive 30 may be applied to the first glass mat layer 22A and allowed to be impregnated. The adhesive 30 may be applied to the second glass mat layer 22B. In this case, the adhesive 30 may be applied to the second glass mat layer 22B from both sides, or only from one side (from the side facing the polyurethane foam layer 21 or the skin film 24). The adhesive 30 may be applied to the second glass mat layer 22B and allowed to be impregnated. In this embodiment, the adhesive 30 is not applied to the skin layer (the knit layer 23 and the skin film 24) before the skin layer is laminated onto the glass mat layer 22, but it is possible to apply the adhesive.

[0019] When the lamination process results in a laminate 26 (see FIG. 4) in which the above-mentioned multiple layers (polyurethane foam layer 21, pair of glass mat layers 22, knit layer 23, and skin film 24) are overlapped, a pressing process is then performed in which the laminate 26 is press-molded. Note that, before the pressing process, the laminate 26 is appropriately cut to fit the size of the molded ceiling 10 to be manufactured. In the example of this embodiment, the layers of this laminate 26 are not pressed against each other, but are simply maintained in an overlapping state.

[0020] In the press process of this embodiment, the laminate 26 is heat-press molded by an upper die 71 and a lower die 72 of a mold 70 shown in Fig. 5. As a result, the laminate 26 is molded into a predetermined shape (e.g., the shape of the ceiling of a vehicle compartment) (see Fig. 6), and the adhesive 30 hardens to bond the layers of the laminate 26 together. In this way, the molded ceiling 10 is obtained.

[0021] Since the adhesive 30 can pass through the glass mat layer 22, if the adhesive 30 is present somewhere between the polyurethane foam layer 21 and the knit layer 23, the polyurethane foam layer 21 and the first glass mat layer 22A, and the first glass mat layer 22A and the knit layer 23 can be bonded together by pressing the laminate 26. Similarly, if the adhesive 30 is present somewhere between the polyurethane foam layer 21 and the skin film 24, the polyurethane foam layer 21 and the second glass mat layer 22B, and the second glass mat layer 22B and the skin film 24 can be bonded together.

[0022] Incidentally, in a conventional method for manufacturing a molded ceiling, when a glass mat layer 22 is superimposed on a base material such as a polyurethane foam layer 21, and a skin layer is further superimposed on the glass mat layer 22 from the outside, an adhesive 30 is applied only to the glass mat layer 22 before superposition. Here, it is considered to use a knit layer 23 as a skin layer on the passenger compartment side in order to improve the texture of the interior surface of the molded ceiling, but when the knit layer 23 is used as the skin layer, a problem occurs in that the adhesion between the glass mat layer 22 and the knit layer 23 becomes insufficient. To solve this problem, it is considered to increase the amount of adhesive 30 applied to the glass mat layer 22, but in this case, a situation occurs in which the adhesive 30 is likely to seep out through the knit layer 23 during press molding.

[0023] In response to this, the inventors of the present application have found, after extensive research, that when overlapping the laminated structure of the molded ceiling 10, it is possible to ensure the adhesion of the knit layer 23 while suppressing the bleeding of the adhesive 30 during press molding by applying the adhesive 30 to the overlapping surface of the polyurethane foam layer 21 in advance and overlapping the glass mat layer 22 on the polyurethane foam layer 21 in this state. In this way, by applying the adhesive 30 to the polyurethane foam layer 21 in advance, it is possible to increase the amount of adhesive 30 between the polyurethane foam layer 21 and the knit layer 23 without increasing the amount of adhesive 30 applied to the glass mat layer 22 closer to the knit layer 23, and therefore it is possible to ensure the adhesion of the knit layer 23 and the glass fiber layer. In particular, in the manufacturing method of the molded ceiling 10 of this embodiment, the polyurethane foam layer 21 and the first glass mat layer 22A are overlapped in a state in which the adhesive 30 is applied (for example, coated) to both the overlapping surface of the polyurethane foam layer 21 that faces the first glass mat layer 22A and the first glass mat layer 22A. Considering manufacturing efficiency, it is generally considered that the adhesive 30 should be applied only to the glass mat layer 22 (first glass mat layer 22) that is superimposed on both the polyurethane foam layer 21 and the skin layer (knit layer 23). However, the inventors of the present application dared to apply the adhesive 30 not only to the glass mat layer 22 but also to the surface of the polyurethane foam layer 21 that is superimposed on the glass mat layer 22, a method that would not be adopted in terms of efficiency and the like from the conventional technical common sense, and a method that is difficult to predict whether good results will be obtained. As a result, they were able to invent a manufacturing method that achieves both the difficult-to-achieve adhesiveness of the knit layer 23 and the suppression of the adhesive 30 from seeping out, and has excellent effects that could not be predicted from the conventional technical level.

[0024] In addition, the surface of the knit layer 23 facing the first glass mat layer 22A is brushed, which makes it possible to increase the adhesion between the knit layer 23 and the adjacent layer (first glass mat layer 22A in this embodiment).

[0025] As another method for ensuring the adhesiveness of the knit layer 23, a surface material (e.g., nonwoven fabric, slab urethane, etc.) that is easily bonded to both the knit layer 23 and the glass fiber layer may be attached to the back surface of the knit layer 23 (the surface facing the glass mat layer 22) and the surface material and the glass fiber layer may be bonded to each other, although this method requires a higher manufacturing cost than the above method. Even with this method, if a knit material through which the adhesive 30 easily penetrates is used for the skin layer, the adhesive 30 may seep out to the outside of the skin layer during press molding. In contrast, by attaching the adhesive 30 to the polyurethane foam layer 21 as in the manufacturing method of the molded ceiling 10 of this embodiment, it is possible to reduce the amount of adhesive 30 attached to the glass mat layer 22, which is closer to the skin layer, and it is possible to suppress the adhesive 30 from seeping out to the outside of the skin layer during press molding.

[0026] As described above, in the manufacturing method of the molded ceiling 10 of this embodiment, the glass mat layer 22 is superimposed on the polyurethane foam layer 21 with adhesive 30 applied to the surface of the polyurethane foam layer 21 that is to be superimposed on the first glass mat layer 22A, thereby making it possible to reduce the occurrence of defects.

[0027] [Other embodiments] (1) In the lamination step, the polyurethane foam layer 21 and the first glass mat layer 22A may be laminated together in a state in which the adhesive 30 is not applied to the first glass mat layer 22A. Also, the polyurethane foam layer 21 and the second glass mat layer 22B may be laminated together in a state in which the adhesive 30 is not applied to the second glass mat layer 22B.

[0028] (2) In the lamination step, the polyurethane foam layer 21 and the second glass mat layer 22B may be laminated together without the adhesive 30 being applied to the surface of the polyurethane foam layer 21 that is to be laminated with the second glass mat layer 22B. In this case, it is sufficient that the adhesive 30 is applied in advance to the second glass mat layer 22B or the skin film 24. Note that by applying the adhesive 30 in advance to the polyurethane foam layer 21 as in the first embodiment, the rigidity of the molded ceiling 10 can be increased.

[0029] (3) In the above embodiment, at least one of the second glass mat layer 22B and the skin film 24 does not have to be provided.

[0030] (4) The adhesives 30 that bond adjacent layers in the laminated structure of the molded ceiling 10 do not all need to be the same, and the adhesives 30 that bond some layers together may be different from the adhesives 30 that bond other layers together. For example, in the lamination process, the adhesives 30 that are applied to the polyurethane foam layer 21 and the first glass mat 22A before they are superimposed on each other may be different types of adhesives 30 applied to the polyurethane foam layer 21 and the first glass mat layer 22A.

[0031] (5) The polyurethane foam layer 21 does not have to have a single-layer structure, and may have a laminated structure made up of multiple layers. In the molded ceiling 10, a layer made of a foamed resin, not limited to polyurethane resin, may be provided at the position of the polyurethane foam layer 21.

[0032] (6) In the above embodiment, the glass fiber layer laminated on the polyurethane foam layer 21 is the glass mat layer 22, but it may be a glass cloth layer. Also, instead of the glass fiber layer laminated on the polyurethane foam layer 21, a fiber layer made of other fibers may be used.

[0033] (7) In the above embodiment, the article formed by laminating a first glass mat layer 22A and an interior knit layer 23 together with an adhesive 30 on one side of a polyurethane foam layer 21 and heat pressing it was a molded ceiling 10 for a vehicle, but it may also be another article.

[0034] <Additional Notes> The following describes the feature groups extracted from the above-described embodiments, while indicating their effects, etc., as necessary. Note that, in the following, for ease of understanding, the corresponding configurations in the above-described embodiments are appropriately indicated in parentheses, but these feature groups are not limited to the specific configurations indicated in parentheses.

[0035] For example, the following group of features relate to a manufacturing method for a molded ceiling for a vehicle, and can be considered to have been conceived in response to the problem that "depending on the material of the molded ceiling, problems may arise with the conventional manufacturing method" in the background art that "various molded ceilings have been developed in the past (see, for example, JP 2000-272433 (paragraphs

[0019] to

[0022] , etc.)." In addition, a new manufacturing method for a molded ceiling is required.

[0036] [Feature 1] A method for manufacturing a molded ceiling, comprising laminating a glass mat layer (a first glass mat layer 22A) and an interior knit layer together with an adhesive on one surface of a polyurethane foam layer, and heat pressing the laminate to form a molded ceiling for a vehicle, comprising: A method for manufacturing a molded ceiling, comprising the steps of: overlapping said glass mat layer on said polyurethane foam layer with said adhesive applied to the surface of said polyurethane foam layer that will be overlapped with said glass mat layer;

[0037] In this feature, the glass mat layer is superimposed on the polyurethane foam layer with an adhesive applied to the surface of the polyurethane foam layer that is to be superimposed on the glass mat layer. This makes it possible to suppress the occurrence of defects in a molded ceiling in which the glass mat layer and the knit layer for interior use are laminated together with the adhesive on one surface of the polyurethane foam layer and then heat-pressed.

[0038] [Feature 2] The method for manufacturing a molded ceiling according to feature 1, wherein the knit layer is superimposed on the glass mat layer with the surface facing the glass mat layer being brushed.

[0039] According to this feature, it is possible to improve the adhesion between the knit layer and the glass mat layer.

[0040] [Feature 3] 3. The method for producing a molded ceiling according to claim 1 or 2, wherein the glass mat layer is superimposed on the polyurethane foam layer and the knitted layer while the adhesive is applied to the glass mat layer.

[0041] [Feature 4] A method for manufacturing a molded ceiling described in any one of features 1 to 3, in which the polyurethane foam layer and the glass mat layer are laminated to each other with the adhesive applied to each of their mutual overlapping surfaces.

[0042] [Feature 5] A method for manufacturing a molded ceiling described in any one of features 1 to 4, in which the adhesive is applied to the overlapping surface of the glass mat layer with the knit layer, and the glass mat layer and the knit layer are laminated together.

[0043] [Feature 6] A manufacturing method for a molded ceiling described in any one of features 1 to 5, in which the adhesive is applied to the overlapping surface of the polyurethane foam layer with the glass mat layer, and the polyurethane foam layer, the glass mat layer, and the knit layer are laminated in a state in which the adhesive is applied to both sides of the glass mat layer.

[0044] [Feature 7] A method for manufacturing a molded ceiling according to any one of features 1 to 6, in which, before the heat pressing is performed, a glass mat layer (second glass mat layer 22B) and a skin film are laminated together with an adhesive on the other side of the polyurethane foam layer opposite the glass mat layer and the knit layer, and all layers from the knit layer to the skin film are heat pressed at once.

[0045] [Feature 8] A method for manufacturing a molded ceiling according to any one of features 1 to 7, wherein a liquid thermosetting adhesive is used as the adhesive.

[0046] [Feature 9] 9. The method for producing a molded ceiling according to claim 8, wherein the adhesive comprises a polyisocyanate compound.

[0047] [Feature 10] A method for manufacturing a molded ceiling, in which a glass mat layer and the knit layer are laminated on the polyurethane foam layer from above, A method for manufacturing a molded ceiling described in any one of features 1 to 9, in which the glass mat layer is superimposed on the polyurethane foam layer from above with the adhesive applied to the upper surface of the polyurethane foam layer.

[0048] [Feature 11] A molded ceiling for a vehicle, in which a glass mat layer (a first glass mat layer 22A) and an interior knit layer are laminated together with an adhesive on one surface of a polyurethane foam layer, A molded ceiling in which the knit layer has a surface facing the glass mat layer that is brushed.

[0049] In addition, although specific examples of the technology included in the scope of the claims are disclosed in this specification and drawings, the technology described in the claims is not limited to these specific examples, but includes various modifications and variations of the specific examples, as well as parts of the specific examples taken alone. [Explanation of symbols]

[0050] 10 Molded ceiling 21 Polyurethane foam layer 22 Glass mat layer 22A 1st glass mat layer 22B 2nd glass mat layer 23 Knitted Layer 24 Skin Film 30 Adhesive 90 vehicles

Claims

1. A method for manufacturing a molded ceiling, comprising laminating a glass mat layer and an interior knit layer together with an adhesive on one surface of a polyurethane foam layer, and heat pressing the laminate to form a molded ceiling for a vehicle, comprising: A method for manufacturing a molded ceiling, comprising the steps of: overlapping said glass mat layer on said polyurethane foam layer with said adhesive applied to the surface of said polyurethane foam layer that will be overlapped with said glass mat layer;

2. The method for manufacturing a molded ceiling according to claim 1, wherein the knit layer is superimposed on the glass mat layer with the surface facing the glass mat layer being brushed.

3. 3. The method for manufacturing a molded ceiling according to claim 1, wherein the glass mat layer is superimposed on the polyurethane foam layer and the knitted layer while the adhesive is applied to the glass mat layer.

4. 3. The method for manufacturing a molded ceiling according to claim 1, wherein the polyurethane foam layer and the glass mat layer are laminated together with the adhesive applied to each of their mutually overlapping surfaces.

5. 3. The method for manufacturing a molded ceiling according to claim 1, wherein the adhesive is applied to the surface of the glass mat layer that overlaps with the knit layer, and the glass mat layer and knit layer are laminated together.

6. A method for manufacturing a molded ceiling as described in claim 1 or 2, wherein the adhesive is applied to the overlapping surface of the polyurethane foam layer with the glass mat layer, and the polyurethane foam layer, the glass mat layer and the knit layer are laminated with the adhesive applied to both sides of the glass mat layer.

7. 3. A method for manufacturing a molded ceiling as described in claim 1 or 2, wherein before the heat pressing is performed, a glass mat layer and a skin film are laminated together with an adhesive on the other side of the polyurethane foam layer opposite the glass mat layer and the knit layer, and all layers from the knit layer to the skin film are heat pressed at once.

8. 3. The method for manufacturing a molded ceiling according to claim 1, wherein the adhesive is a liquid thermosetting adhesive.

9. The method of claim 8, wherein the adhesive comprises a polyisocyanate compound.

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