Backing material of vehicle molding ceiling and vehicle molding ceiling

Abstract

To provide a backing material of a vehicle molding ceiling and the vehicle molding ceiling capable of suppressing seeing-through or cracks of a heat shielding layer and providing stable heat shielding effect.SOLUTION: Provided is a backing material 3 of a vehicle molding ceiling 10 arranged between a base material 2 of the vehicle molding ceiling 10 and a vehicle body panel P. The backing material 3 includes: a fiber layer 12 being a non-woven fabric having a sheet shape facing the vehicle body panel P side; and a heat shielding film layer 13 formed of a metal film integrated with one surface of the fiber layer 12 and reflecting radiation heat from the vehicle body panel P side. The backing material 3 further includes a barrier layer 16 stacked on the fiber layer 12 on the base material 2 side via an adhesive resin 15 and blocking or suppressing air permeation with the base material 2. Since the nonwoven fabric has high tensile strength and low elasticity, the nonwoven fabric can suppress elongation of the backing material at the time of molding of the vehicle molding ceiling 10. Since the heat shielding film layer 13 is deformed integrally with the fiber layer 12, a difference in elongation between the fiber layer 12 and the heat shielding film layer 13 is hard to occur even in a portion where the shape of the vehicle molding ceiling 10 changes.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] The present invention relates to a backing for a molded vehicle headliner and to a molded vehicle headliner. [Background technology]

[0002] Various types of molded ceiling materials for vehicles have been known in the past. For example, since the interior of an automobile can become very hot during extremely hot weather, molded ceiling materials with heat-shielding and heat-insulating functions have been developed in recent years. The ceiling panels of a vehicle body have a large surface area, and the radiant heat of sunlight irradiating the ceiling panels has a significant impact on the rise in the temperature inside the vehicle. Furthermore, as the temperature inside the vehicle interior rises, the energy load caused by the use of the air conditioner also increases. Therefore, as one means of suppressing the rise in temperature inside the vehicle interior, ceiling molding materials with heat-shielding functions have been installed.

[0003] For example, Patent Document 1 discloses a far-infrared reflective film used as a backing material for a vehicle ceiling material. The far-infrared reflective film reflects radiant heat from the ceiling panel, thereby suppressing heat input into the vehicle interior. Patent Document 2 discloses a vehicle ceiling material including an infrared reflective layer disposed as a backing material. As an example of the infrared reflective layer, an aluminum vapor deposition film in which an aluminum vapor deposition layer is formed on the surface of a base film is disclosed. [Prior art documents] [Patent documents]

[0004] [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 [Problem to be solved by the invention]

[0005] Incidentally, aluminum vapor-deposited films conventionally used as backing materials for vehicle ceiling materials often have a structure in which a resin film made from a material such as polyethylene terephthalate or polypropylene is used as a base film, and aluminum is vapor-deposited on the surface of the base film to form a heat-shielding layer. However, these base films have the property of stretching well when pulled, and if the base film stretches more than expected when the vehicle ceiling material is molded, there is a tendency for the stretching of the heat-shielding layer to differ from the stretching of the base film. Therefore, at areas with large undulations or changes in shape, such as inflection points in the molded body of the vehicle ceiling material, excessive pressure can cause the heat-shielding layer to shrink or crack, raising concerns about partial reductions in the heat-shielding performance of the vehicle ceiling material.

[0006] The present invention was devised in consideration of the above points, and aims to provide a backing material for a molded vehicle ceiling and a molded vehicle ceiling that can suppress scale and cracking in the heat-shielding layer and achieve a stable heat-shielding effect. [Means for solving the problem]

[0007] One feature of the backing material for a molded vehicle ceiling that solves the above-mentioned problems is a backing material that is arranged between the substrate of the molded vehicle ceiling and a vehicle body panel, and has: a fiber layer that is a sheet-like nonwoven fabric facing the vehicle body panel side; a heat-shielding film layer that is composed of a metal film integrated on one side of the fiber layer and reflects radiant heat from the vehicle body panel side; and a barrier layer that is laminated on the substrate side of the fiber layer via an adhesive resin and has the function of blocking or suppressing ventilation between the substrate and the fiber layer.

[0008] One feature and advantage of the above configuration is that the backing material includes a fiber layer facing the vehicle body panel and a barrier layer laminated via an adhesive resin to the interior side of the fiber layer. The fiber layer is a sheet-like nonwoven fabric, and a heat-shielding film layer is formed on one side of the fiber layer so as to be integrated with the fiber layer. The nonwoven fabric constituting the fiber layer has high tensile strength and is less stretchable than a resin film, thereby suppressing the stretching of the backing material during the molding of the vehicle headliner. Furthermore, because the heat-shielding film layer deforms integrally with the fiber layer, there is little difference in the stretching between the fiber layer and the heat-shielding film layer, even in areas with large undulations or shape changes. In other words, excessive tension on the heat-shielding film layer is suppressed, preventing scaling and cracking of the heat-shielding film layer. Therefore, by including a backing material of this configuration, the vehicle headliner can achieve a stable heat-shielding effect.

[0009] In the backing material of the above-mentioned molded vehicle headliner, the fibrous layer may be selected from a spunbond nonwoven fabric and a spunlace nonwoven fabric.

[0010] One feature and advantage of the above-described configuration is that a spunbond nonwoven fabric or a spunlace nonwoven fabric is selected as the fiber layer. These nonwoven fabrics have excellent surface smoothness and are easy to apply heat-shielding processing such as vapor deposition or printing. Therefore, they are suitable as a fiber layer that integrates the heat-shielding film layer.

[0011] In the backing material of the above-mentioned molded vehicle ceiling, the heat-shielding film layer may be made of an aluminum vapor deposition film.

[0012] One feature and advantage of the above configuration is that aluminum is vapor-deposited on one side of the fiber layer. Because aluminum has a high infrared reflectivity, using an aluminum vapor-deposited film as the heat-shielding film layer can improve the heat-shielding effect. Furthermore, forming the heat-shielding film layer by vapor deposition makes it easier to control the film thickness, such as by forming a thinner film layer. Therefore, it is possible to form a heat-shielding film layer that meets the specifications of the vehicle molded ceiling.

[0013] The backing material of the above-mentioned molded vehicle ceiling may be configured such that the heat-shielding film layer is formed on the surface of the fiber layer facing the vehicle body panel, and a protective layer is laminated on the heat-shielding film layer facing the vehicle body panel.

[0014] One feature and advantage of the above configuration is that the heat-shielding film layer faces the vehicle body panel. This can improve the efficiency of reflecting radiant heat from the vehicle body panel. That is, the heat-shielding effect can be improved. Furthermore, the provision of the protective layer can prevent aluminum particles constituting the heat-shielding film layer from falling off.

[0015] A molded vehicle ceiling that solves the above problem is a molded ceiling that includes the above backing material.

[0016] One feature and advantage of the above configuration is that when the molded vehicle ceiling is press-molded, there is little difference in elongation between the fiber layer and the heat-shielding film layer even in areas of the molded vehicle ceiling that have large undulations or changes in shape, which makes it possible to prevent scaling and cracking of the heat-shielding film layer. Therefore, it is possible to provide a molded vehicle ceiling with stable heat-shielding effect. [Effects of the Invention]

[0017] By adopting the above-mentioned configuration, the present invention can provide a backing material for a molded vehicle headliner and a molded vehicle headliner that can suppress flaking and cracking of the heat shielding layer and achieve a stable heat shielding effect. [Brief explanation of the drawings]

[0018] [Figure 1] 1 is a diagram schematically illustrating a molded ceiling mounted on a vehicle. [Figure 2] 1 is a diagram illustrating a cross-sectional structure of a vehicle ceiling mold according to an embodiment of the present invention; [Figure 3] FIG. 2 is a diagram schematically illustrating the cross-sectional structure of a backing material according to an embodiment. [Figure 4] FIG. 10 is a diagram schematically illustrating the cross-sectional structure of a backing material according to another embodiment. [Figure 5] FIG. 10 is a diagram showing the state in which a tensile force is applied to the backing material according to the example. [Figure 6]FIG. 10 is a diagram showing a state in which a tensile force is applied to a backing material according to a comparative example. DETAILED DESCRIPTION OF THE INVENTION

[0019] Hereinafter, an embodiment of the present invention will be described with reference to the drawings. A vehicle is configured with a ceiling panel P (vehicle body panel) made of steel plate as a roof. As shown in FIG. 1, a molded vehicle ceiling 10 according to this embodiment is a ceiling interior material that is attached to the interior side of the ceiling panel P. As shown in FIG. 2, the molded vehicle ceiling 10 is formed by heating and pressure molding a laminate including a base layer 2 (base material), a backing material 3, and a skin material 4, for example, by a heat press. Note that in the schematic cross-sectional views of FIGS. 2 to 4, the upper side of the paper faces the ceiling panel P, and the lower side faces the interior side of the vehicle.

[0020] The backing material 3 is disposed on the ceiling panel P side of the base material layer 2. As shown in Fig. 3, the backing material 3 has 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 side). The fiber layer 12 and the barrier layer 16 are surface-bonded together by an adhesive resin layer 15 (adhesive resin). The backing material 3 further has a heat-shielding film layer 13 formed integrally with the fiber layer 12 on one surface of the fiber layer 12.

[0021] The fiber layer 12 may be, for example, a spunbonded nonwoven fabric or a spunlaced nonwoven fabric. Spunbonded nonwoven fabrics are formed by directly stacking continuous, long fibers obtained by melting and spinning a raw resin to form a sheet-like fiber web, and then bonding the fiber webs in multiple layers using a thermal bonding method, which involves thermocompression bonding. Spunbonded nonwoven fabrics have high tensile strength due to the use of long fibers. Spunlaced nonwoven fabrics are formed, for example, by forming a sheet-like fiber web from staple fibers using a dry method, and then spraying a high-pressure water stream onto the fiber web in a columnar fashion to entangle the fibers within the web. Spunlaced nonwoven fabrics are formed by tightly entangling the fibers, thereby achieving high strength. Furthermore, the surfaces of spunbonded and spunlaced nonwoven fabrics are smooth, making them amenable to heat-shielding treatments such as vapor deposition and printing, as described below.

[0022] For example, PET (polyester) fiber, PP (polypropylene) fiber, etc. are selected as the main raw material of the nonwoven fabric constituting the fiber layer 12. Various synthetic fiber nonwoven fabrics such as polyamide-based, polyester-based, and polyacrylonitrile-based can be used for the fiber layer 12.

[0023] The heat-shielding film layer 13 is made 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-shielding film layer 13 has the function of reflecting radiant heat from the ceiling panel P. For example, as shown in FIG. 3 , the heat-shielding film layer 13 is formed integrally with the fiber layer 12 on the surface of the fiber layer 12 facing the base material layer 2. The heat-shielding film layer 13 is made of, for example, an aluminum vapor-deposited film. The aluminum vapor-deposited film is formed by heating and evaporating aluminum under high vacuum conditions using an electron beam or high-frequency induction, and adhering fine aluminum particles to one surface of the fiber layer 12.

[0024] The heat shielding film layer 13 may be formed by printing instead of vapor deposition. For example, an aluminum film can be formed by gravure printing. In gravure printing, ink mixed with aluminum particles is applied to the cells of a cylindrical intaglio plate and then transferred to one side of the fiber layer 12. In this way, an aluminum film is formed as the heat shielding film layer 13.

[0025] The barrier layer 16 is a non-breathable film, and for example, a non-oriented polypropylene film is selected. Non-oriented polypropylene (CPP) is a polypropylene material that has not been stretched, and has the property of stretching when pulled. The barrier layer 16 has tensile strength, is tear-resistant, and has the function of blocking or suppressing ventilation between the barrier layer 16 and the base layer 2. The adhesive resin layer 15 is provided to bond the barrier layer 16 and the fiber layer 12, and for example, extruded polypropylene is selected.

[0026] As shown in Fig. 4, the backing material 3 may have a configuration in which the heat-shielding film layer 13 is formed on the surface of the fiber layer 12 facing the ceiling panel P. In this configuration, a protective layer 18 is laminated on the ceiling panel P side of the heat-shielding film layer 13. The protective layer 18 is provided to prevent the aluminum particles that make up the heat-shielding film layer 13 from falling off, and is formed by laminating, for example, acrylic resin or urethane.

[0027] 2, the base material layer 2 includes a porous core material 6 and fiber reinforcement layers 7 and 8 laminated on both sides of the core material 6, and is solidified with a thermosetting adhesive or the like. The core material 6 is provided to maintain the shape and ensure the rigidity of the molded vehicle ceiling 10, and is molded into a planar shape that conforms to the surface of the ceiling panel P. The core material 6 in this embodiment is selected to be a semi-rigid layer of urethane foam made of urethane resin foam.

[0028] A first fiber reinforcement layer 7 is laminated on the surface of the core material 6 facing the ceiling panel P, and a second fiber reinforcement layer 8 is laminated on the surface facing the interior of the vehicle. The first and second fiber reinforcement layers 7, 8 are provided to maintain the shape and ensure the rigidity of the vehicle molded ceiling 10. These fiber reinforcement layers 7, 8 have their surfaces coated with or impregnated with a thermosetting adhesive (thermoplastic resin), and are adhered to both sides of the core material 6, respectively. A glass fiber mat is selected for the first and second fiber reinforcement layers 7, 8. The glass fiber mat is formed into a sheet by solidifying chopped strands of inorganic glass fiber cut to an appropriate length with an appropriate binder. In addition, a nonwoven fabric that protects the surface of the second fiber reinforcement layer 8 may be laminated on the interior side of the second fiber reinforcement layer 8. For example, a needle-punched nonwoven fabric is selected for this nonwoven fabric.

[0029] These fiber-reinforced layers 7, 8 may be made of uncut glass fibers solidified with a binder (continuous mat). Alternatively, they may be made of spunlace, spunbond nonwoven fabric, glass paper, or glass fiber woven fabric. The basis weight in the embodiment can be selected to meet the required strength and other various conditions.

[0030] The fiber reinforcing material used in these fiber reinforcing layers 7, 8 may be an inorganic fiber such as chopped strands, or an organic fiber such as jute, kenaf, ramie, hemp, sisal, or bamboo, which is a natural fiber appropriately selected and formed into a sheet or mat shape using a binder such as acrylic or needle processing.

[0031] The thermosetting adhesive is selected from thermosetting resins made of isocyanate resins. Isocyanates are suitable because they are compatible with the core material 6 made of the semi-rigid urethane foam layer. The thermosetting adhesive is not limited to isocyanate resins and can be selected as appropriate. The thermosetting adhesive is applied by spraying, roll coating, or the like. As described above, by laminating the fiber reinforcement layers 7, 8 containing thermosetting resin and the core material 6, the strength of the vehicle molded ceiling 10 can be increased.

[0032] The skin material 4 is disposed on the interior side of the base material layer 2 as a part that is responsible for the design surface of the vehicle molded ceiling 10. The skin material 4 is selected, for example, from a laminate of a surface layer and a urethane foam sheet. The surface layer can be made of various materials, such as fabric, cloth, knitted fabric, woven fabric, nonwoven fabric, thin woolen fabric, synthetic leather, artificial leather, genuine leather, etc. The urethane foam sheet is laminated by applying a soft layer made of urethane resin foam to the vehicle molded ceiling 10 to give it a soft feel. Note that a configuration without a urethane foam sheet may also be used.

[0033] <Comparison of backing material strength> The backing materials according to the Examples and the backing materials according to the Comparative Examples were compared in terms of elongation, scale and crack occurrence when a tensile force was applied. [Example] This backing material is made by laminating a non-oriented polypropylene film (barrier layer 16) via a resin adhesive (resin adhesive layer 15) to a spunbond nonwoven fabric (fiber layer 12) that has been subjected to aluminum vapor deposition as a heat-shielding film layer 13. [Comparative Example] Backing material made of conventional aluminum vapor deposition film. As shown in Figure 5, no voids or cracks were observed in the thermal barrier film layer 13 of the backing material of the example. Furthermore, the backing material of the example had approximately one-third of the longitudinal and lateral elongation of the backing material of the conventional product. As shown in Figure 6, the conventional backing material had voids and cracks in the aluminum vapor deposition film, for example, within the range indicated by A.

[0034] <Effects of the embodiment> According to the backing material 3 of the molded vehicle ceiling 10 according to the above embodiment, the backing material 3 includes a fiber layer 12 facing the ceiling panel P (vehicle body panel) and a barrier layer 16 laminated via an adhesive resin layer 15 (adhesive resin) on the surface of the fiber layer 12 facing the base material layer 2 (the vehicle interior side). The fiber layer 12 is a sheet-like nonwoven fabric, and a heat-shielding film layer 13 is formed on one surface thereof so as to be integrated with the fiber layer 12. The nonwoven fabric constituting the fiber layer 12 has high tensile strength and is less stretchable than a resin film, which can suppress elongation of the backing material 3 during molding of the molded vehicle ceiling 10. Furthermore, because the heat-shielding film layer 13 deforms integrally with the fiber layer 12, differences in elongation between the fiber layer 12 and the heat-shielding film layer 13 are unlikely to occur even in areas with large undulations or changes in shape. In other words, excessive pulling on the heat-shielding film layer 13 is suppressed, which can prevent the heat-shielding film layer 13 from being chipped or cracked. Therefore, by providing the backing material 3 with this configuration, the vehicle molded ceiling 10 can obtain a stable heat-shielding effect.

[0035] For the backing material 3 according to the above embodiment, a spunbond nonwoven fabric or a spunlace nonwoven fabric is selected as the heat shielding film layer 13. Spunbond nonwoven fabric and spunlace nonwoven fabric have excellent surface smoothness and are easy to apply heat shielding processes such as vapor deposition and printing. Therefore, they are suitable as the fiber layer 12 to which the heat shielding film layer 13 is integrated.

[0036] The backing material 3 according to the above embodiment is subjected to aluminum vapor deposition as the heat-shielding film layer 13. Because aluminum has a high infrared reflectivity, forming the heat-shielding film layer 13 as an aluminum vapor deposition film can improve the heat-shielding effect. Furthermore, forming the heat-shielding film layer 13 by vapor deposition makes it easier to control the film thickness, for example, to form a thinner film layer. Therefore, the heat-shielding film layer 13 can be formed according to the specifications of the vehicle molded ceiling 10.

[0037] In the backing material 3 according to the above embodiment, by forming the heat-shielding 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 heat-shielding effect can be improved. Furthermore, by providing the protective layer 18 on the ceiling panel P side of the heat-shielding film layer 13, it is possible to prevent the aluminum particles that make up the heat-shielding film layer 13 from falling off.

[0038] By using the backing material 3 according to the above embodiment in the vehicle molded ceiling 10, when the vehicle molded ceiling 10 is press-molded, differences in elongation between the fiber layer 12 and the heat-shielding film layer 13 are unlikely to occur even in areas of the vehicle molded ceiling 10 with large undulations or changes in shape, preventing scaling and cracking of the heat-shielding film layer 13. Therefore, a vehicle molded ceiling 10 with stable heat-shielding effect can be provided.

[0039] The backing material 3 according to the above embodiment has a barrier layer 16 made of an air-impermeable film on the side of the base layer 2. This allows the backing material 3 to have the function of blocking or suppressing ventilation between the base layer 2 and the backing material 3. In other words, the backing material 3 has the air-impermeable function of conventional backing materials, and also has the function of suppressing elongation of the backing material 3 during molding of the vehicle headliner 10.

[0040] In the vehicle molded ceiling 10 according to the above embodiment, the heat-shielding film layer 13 of the backing material 3 has the function of reflecting infrared rays. With this configuration, the radiant heat of sunlight S received by the ceiling panel P is reflected, thereby suppressing heat input into the vehicle interior. Therefore, it is possible to suppress the temperature rise inside the vehicle interior due to the radiant heat of sunlight S. Furthermore, it is possible to reduce energy consumption due to the use of the air conditioner.

[0041] The backing material for the vehicle molded ceiling and the vehicle molded ceiling of the present invention are not limited to the appearance and configuration described in the above embodiment, and can be implemented in various other forms by various modifications, additions, deletions, and combinations of configurations within the scope that does not change the gist of the present invention.

[0042] Although the base layer according to the above embodiment is configured by laminating a urethane foam core and a fiber reinforcement, various configurations are possible. For example, the base layer may be configured by a molded body in which nonwoven fabric is laminated on both sides of a core containing glass fiber and thermoplastic resin, or by a molded nonwoven fabric.

[0043] The heat shielding film layer according to the present invention is not limited to aluminum, but may include other metal films, such as copper, that exhibit a heat shielding effect by reflecting infrared rays. [Explanation of symbols]

[0044] 2 Base material layer (base material) 3 Backing material 4 Skin material 6 Core material 7 First fiber reinforcement layer 8 Second fiber reinforcement layer 10. Molded headliner for vehicle 12 Fiber layer 13 Heat-shielding film layer 15 Adhesive resin layer (adhesive resin) 16 Barrier Layer 18 Protective layer

Claims

1. A backing material for a vehicle molded headliner disposed between a substrate of the vehicle molded headliner and a vehicle body panel, comprising: a fiber layer that is a sheet-like nonwoven fabric facing the vehicle body panel; a heat-shielding film layer formed of a metal film integrated on one surface of the fiber layer, the heat-shielding film layer reflecting radiant heat from the vehicle body panel side; A backing material for a molded vehicle ceiling, comprising: a barrier layer laminated to the substrate side of the fiber layer via an adhesive resin and having the function of blocking or suppressing air passage between the fiber layer and the substrate.

2. 2. A backing material for a vehicle molded headliner according to claim 1, The backing of a molded vehicle headliner, wherein the fibrous layer is selected from a spunbonded nonwoven fabric and a spunlaced nonwoven fabric.

3. 3. A backing material for a vehicle molded headliner according to claim 2, The heat-shielding film layer is a backing material for a molded vehicle ceiling, the backing material being made of an aluminum vapor deposition film.

4. 4. A backing material for a vehicle molded headliner according to claim 3, the heat-shielding film layer is formed on the surface of the fiber layer facing the vehicle body panel, A backing for a molded vehicle headliner, comprising a protective layer laminated to the body panel side of the heat-shielding film layer.

5. A molded headliner for a vehicle, comprising: A moulded headliner for a vehicle comprising a backing material according to any one of claims 1 to 4.

Images