Molded ceiling material for vehicles and method for manufacturing the same

Abstract

To provide a molded ceiling material for vehicles that can suppress the peeling of vehicle parts. [Solution] A panel-shaped molded ceiling material 10 for a vehicle, which is disposed on the interior side of the roof panel 2 of a vehicle 1, comprises a base layer 20, a first fiber reinforcement layer 21 provided on the interior side of the base layer 20, a second fiber reinforcement layer 22 provided on the roof panel 2 side of the base layer 20, a surface layer 30 provided on the interior side of the first fiber reinforcement layer 21, and a back layer 40 provided on the roof panel 2 side of the second fiber reinforcement layer 22. The back layer 40 has, in order from the interior side, a non-breathable film layer 41 and a nonwoven fabric layer 45. The nonwoven fabric layer 45 contains aluminum.

Description

[Technical Field]

[0001] This invention relates to a molded ceiling material for vehicles such as automobiles and a method for manufacturing the same. [Background technology]

[0002] As a molded ceiling material for vehicles, for example, a material is generally known in which a rigid urethane or the like is used as the base layer, glass fiber reinforcement layers are provided on both sides thereof, and a surface layer and a back layer are provided on the outside of each glass fiber reinforcement layer (Patent Document 1).

[0003] Furthermore, a known vehicle ceiling material comprises a non-breathable film made of synthetic resin and an aluminum vapor-deposited film formed by vapor-depositing aluminum onto the surface of the non-breathable film as the back layer (Patent Document 2). [Prior art documents] [Patent Documents]

[0004] [Patent Document 1] Japanese Patent Publication No. 2009-90548 [Patent Document 2] Japanese Patent Publication No. 2014-91442 [Overview of the project] [Problems that the invention aims to solve]

[0005] Incidentally, vehicle components such as harnesses are sometimes bonded to the back layer of molded ceiling materials for vehicles. However, if an aluminum vapor-deposited film is provided on the back layer, as in the molded ceiling material for vehicles described in Patent Document 2, there is a concern that vehicle components bonded to the aluminum vapor-deposited film may easily peel off.

[0006] The object of the present invention is to provide a molded ceiling material for vehicles that can suppress the peeling of vehicle parts, and a method for manufacturing the same. [Means for solving the problem]

[0007] The invention of claim 1 is a molded ceiling material for a vehicle that is in the shape of a panel and is disposed on the interior side of a roof panel in a vehicle, comprising a base layer, a first fiber reinforcement layer provided on the interior side of the base layer, a second fiber reinforcement layer provided on the roof panel side of the base layer, a surface layer provided on the interior side of the first fiber reinforcement layer, and a back layer provided on the roof panel side of the second fiber reinforcement layer, wherein the back layer has, in order from the interior side, a non-breathable film layer and a nonwoven fabric layer, and the nonwoven fabric layer has aluminum attached to its surface.

[0008] The invention of claim 2 is a molded ceiling material for a vehicle according to claim 1, characterized in that the aluminum is aluminum powder, and the aluminum powder is dispersed and attached to the surface of the nonwoven fabric layer.

[0009] The invention of claim 3 is characterized in that, in the molded ceiling material for vehicles described in claim 2, the aluminum powder is derived from aluminum powder contained in the ink.

[0010] The invention of claim 4 is characterized in that, in the method for manufacturing a molded ceiling material for a vehicle as described in claim 2, one side of a nonwoven fabric sheet forming the nonwoven fabric layer is joined with the non-permeable film layer to form a back layer, ink containing aluminum powder is printed on the other side of the nonwoven fabric sheet, a surface material forming the surface layer, a first glass fiber reinforcing material forming the first fiber reinforcing layer, a core material forming the base material layer, a second glass fiber reinforcing material forming the second fiber reinforcing layer, and the back layer are stacked on top of each other, heated and compressed to form the molded ceiling material for a vehicle in which the surface layer, the first fiber reinforcing layer, the base material layer, the second fiber reinforcing layer, and the back layer are integrated.

[0011] The invention according to claim 5 is a method for manufacturing a molded ceiling material for a vehicle according to claim 2, wherein ink containing the aluminum powder is printed on the surface of the non-woven fabric sheet to form the non-woven fabric layer to which the aluminum powder adheres, and the surface of the non-woven fabric layer on the side where the aluminum powder is not printed is joined to the non-ventilation film layer to form the back surface layer, and the skin material for forming the skin layer, the first glass fiber reinforcing material for forming the first fiber reinforcing layer, the core material for forming the base material layer, the second glass fiber reinforcing material for forming the second fiber reinforcing layer, and further the back surface layer are stacked, heated and compressed to be molded, and the vehicle molded ceiling material in which the skin layer, the first fiber reinforcing layer, the base material layer, the second fiber reinforcing layer and the back surface layer are integrated is manufactured.

[0012] The invention according to claim 6 is a method for manufacturing a molded ceiling material for a vehicle according to claim 4 or 5, wherein the printing is intaglio printing.

[0013] The invention according to claim 7 is a method for manufacturing a molded ceiling material for a vehicle according to claim 6, wherein the intaglio printing is gravure printing.

[0014] In the present invention, the aluminum powder includes aluminum powder, aluminum grains, flaky aluminum, etc., and is hereinafter simply referred to as aluminum powder.

Effects of the Invention

[0015] According to the present invention, it is possible to provide a molded ceiling material for a vehicle capable of suppressing peeling of vehicle parts and a method for manufacturing the same.

Brief Description of the Drawings

[0016] [Figure 1] It is a perspective view of a vehicle provided with a molded ceiling material for a vehicle according to an embodiment of the present invention. [Figure 2] It is a cross-sectional view schematically showing a cross-section of a molded ceiling material for a vehicle according to an embodiment of the present invention. [Figure 3] It is an enlarged photograph of a cross-section of a molded ceiling material for a vehicle according to an embodiment of the present invention. [Figure 4]This is an enlarged photograph of the cross-section of a molded ceiling material for a vehicle according to an embodiment of the present invention, taken at an even greater magnification than that shown in Figure 3. [Figure 5] This is a schematic diagram showing the state of aluminum powder adhering to the fibers of a nonwoven fabric in a molded ceiling material for a vehicle according to an embodiment of the present invention. [Figure 6] This is a schematic diagram showing the process of evaluating handling stability by driving a vehicle with each sample attached to its molded roof. [Figure 7] This figure schematically illustrates the fluctuation state of positive ions in the driving conditions shown in Figure 6. [Figure 8] This figure shows the evaluation results of handling stability during driving tests for each sample. [Modes for carrying out the invention]

[0017] Embodiments of the present invention will be described in detail below with reference to the drawings. The following description of preferred embodiments is essentially illustrative.

[0018] Figure 1 shows a vehicle 1 to which the molded ceiling material 10 for vehicles of the present invention is applied. Figure 2 is a schematic cross-sectional view showing a cross-section of the molded ceiling material 10 for vehicles of the present invention. As shown in Figure 1, the molded ceiling material 10 for vehicles is panel-shaped and is disposed on the interior side of the roof panel 2 in vehicle 1. As shown in Figure 2, the molded ceiling material 10 for vehicles has a first fiber reinforcement layer 21 on the interior side of the base layer 20 and a surface layer 30 on the interior side of the first fiber reinforcement layer 21. Furthermore, the molded ceiling material 10 for vehicles has a second fiber reinforcement layer 22 on the exterior side (roof panel 2 side) of the base layer 20 and a back surface layer 40 on the exterior side (roof panel 2 side) of the second fiber reinforcement layer 22. Note that Figure 2 is an exaggerated and easy-to-understand representation of a part of the cross-section of the molded ceiling material 10 for vehicles.

[0019] As shown in Figure 2, the base layer 20 has a core material (not shown) that forms the base layer 20. The core material is preferably, for example, polyurethane foam, polyethylene foam, etc., but rigid polyurethane foam is particularly preferred.

[0020] The first fiber reinforcement layer 21 and the second fiber reinforcement layer 22 are made of, for example, commonly known glass fiber mats (first glass fiber reinforcement material, second glass fiber reinforcement material). When forming the vehicle's molded ceiling material 10, an isocyanate-based adhesive is applied to the first fiber reinforcement layer 21 and the second fiber reinforcement layer 22 to bond them to the base layer 20, etc.

[0021] The epidermal layer 30 has an epidermal material 32.

[0022] The surface material 32 may be, for example, tricot, soft polyurethane foam, moldable knit, fabric, nonwoven fabric, suede-like synthetic leather, PVC (polyvinyl chloride) leather, TPE (thermoplastic elastomer) sheet, etc.

[0023] The back layer 40, for example, has a non-breathable film layer 41 and a nonwoven fabric layer 45 in order from the base layer 20 side toward the outside of the vehicle interior.

[0024] The non-permeable film layer 41 consists of a non-permeable film 43 (for example, a CPP film). The non-permeable film 43 may be a film made of polyamide resin or the like.

[0025] The nonwoven fabric layer 45 is, for example, a nonwoven fabric sheet 46 made by spunlace-treated a PET resin (polyethylene terephthalate resin) web, on which aluminum powder 52 is randomly and unevenly attached. In the embodiment of the present invention, the aluminum powder 52 is clinging to the fibers 47 of the nonwoven fabric sheet 46. The nonwoven fabric sheet 46 may also be, for example, a spunbond-treated PET resin web.

[0026] Since aluminum powder 52 is randomly and unevenly attached to the surface of the nonwoven fabric sheet 46, it is in a non-conductive state. Therefore, even if a wire harness or the like is attached to the surface of the nonwoven fabric sheet 46, there is no risk of it becoming conductive.

[0027] (Non-woven fabric layer 45) The nonwoven fabric layer 45 is provided to prevent abnormal noise (for example, to prevent abnormal noise caused by interference between the back layer 40 and vehicle parts). The basis weight of the nonwoven fabric layer 45 is 25 g / m². 2 ~50g / m 2 It is preferable to do so.

[0028] (Ink 50) Ink 50 is a general ink containing aluminum powder 52 to be applied, and is not particularly limited. For example, in the wet state during application (printing), an ink with the main component resin at 10% to 20% by weight, solvent at 40% to 90% by weight, aluminum powder at 3% to 5% by weight, auxiliary agents at 1% to 5% by weight, and hardener at 1% to 5% by weight is applicable.

[0029] Ink 50 is a general ink containing aluminum powder 52 to be applied, and is not particularly limited. For example, in the wet state during application (printing), an ink with the main component resin at 10% to 20% by weight, solvent at 40% to 90% by weight, aluminum powder at 3% to 5% by weight, auxiliary agents at 1% to 5% by weight, and hardener at 1% to 5% by weight is applicable.

[0030] The aluminum powder 52 originates from the aluminum powder 52 contained in the ink 50, and the amount of aluminum powder 52 to be attached to the nonwoven fabric sheet 46 can be adjusted as needed depending on the area of ​​the molded ceiling and the vehicle structure. The ratio of aluminum powder 52 in the ink 50 should be set according to the amount of aluminum powder 52. The amount of ink 50 to be applied should be set considering the ease of application and drying of the ink 50.

[0031] The aluminum powder 52 can be any fine particles such as lumpy aluminum particles or flaky aluminum, and is not particularly limited, but it is preferable that the size of the aluminum powder 52 is in the range of, for example, 1 to 150 μm. It is acceptable for there to be some variation in the size of the aluminum powder 52 within the above range.

[0032] (Manufacturing method for molded ceiling material 10 for vehicles) One side of the nonwoven fabric sheet 46 that forms the nonwoven fabric layer 45 is heat-welded together with the non-permeable film layer 41 to form the back layer 40. Next, ink containing aluminum powder 52 is printed (intaglio printing) onto the other side of the nonwoven fabric sheet 46 of the back layer 40. A heat-molded rigid urethane foam sheet is prepared as the base layer 20. The first fiber reinforcement layer 21 and the second fiber reinforcement layer 22 are prepared as sheets formed in a mat shape. The surface layer 30 is prepared from tricot and soft foamed urethane.

[0033] Subsequently, the surface layer 30, the first fiber reinforcement layer 21, the base material layer 20, the second fiber reinforcement layer 22, and the back layer 40 are stacked in order, and then pressed in a heated molding die to form the shape of the vehicle molded ceiling material 10. In other words, the surface material 32 that forms the surface layer 30, the first glass fiber reinforcement material that forms the first fiber reinforcement layer 21, the core material that forms the base material layer 20, the second glass fiber reinforcement material that forms the second fiber reinforcement layer 22, and the back layer 40 are stacked, heated and compressed to form the vehicle molded ceiling material 10 in which the surface layer 30, the first fiber reinforcement layer 21, the base material layer 20, the second fiber reinforcement layer 22, and the back layer 40 are integrated. Note that the molding conditions for the vehicle molded ceiling material 10 are the same as normal molding conditions, so the explanation is omitted here.

[0034] In this invention, aluminum powder is attached to or wrapped around the surface of a nonwoven fabric by methods such as printing an ink containing aluminum powder directly onto the nonwoven fabric. Therefore, when a component is attached to such a surface, it adheres to or wraps around the uneven fibers of the nonwoven fabric, making it difficult to peel off.

[0035] In contrast, conventional technologies tend to result in peeling. The reason for this is explained below. In conventional technology 1, where aluminum vapor-deposited films are bonded together, the aluminum vapor-deposited film forms a flat plane, resulting in parts attached to the surface being prone to peeling. Also, in the case where a film containing aluminum powder (aluminum film) is bonded to another film, the aluminum powder is arranged in parallel with gaps between them. Furthermore, another aluminum film is layered on top to cover these gaps with aluminum powder, resulting in multiple layers of aluminum film. In plan view, it looks as if the aluminum powder is spread out. In this technology as well, the aluminum film layer forms a flat plane, resulting in parts attached to the surface being prone to peeling.

[0036] Furthermore, when the molded roof of the present invention was assembled to a vehicle and test-driven, it became dramatically easier to drive compared to the case of a conventional molded roof, and the handling could be operated smoothly as intended. In other words, it was found that when aluminum powder is attached to the surface of the nonwoven fabric, not only are the attached parts such as wire harnesses and brackets less likely to peel off, but the vehicle's handling stability is greatly improved. The reason for this is that in the present invention, the aluminum powder attached to the nonwoven fabric is separated and dispersed in a mottled manner, so it has a function like a capacitor that temporarily stores electric charge, and the edges of the separated and independent aluminum powder act like discharge terminals (or discharge lines), so many of the aluminum powder particles have excellent charge storage and discharge functions. As a result, many of the aluminum powder particles can repeatedly store and discharge electricity, which is thought to suppress turbulence in the airflow of the roof panel and lead to improved handling stability.

[0037] As will be explained in detail later, in this invention, the aluminum powder adheres to the surface of the nonwoven fabric in accordance with the uneven surface of the nonwoven fabric, so the aluminum powder is dispersed in a three-dimensional manner, facing in various directions. Because each aluminum powder is separated and independently attached to the surface of the nonwoven fabric, it exhibits excellent function as a temporary energy storage function, and since each aluminum powder has an edge, this edge acts like a discharge terminal. In particular, because the aluminum powder is facing in various directions in three dimensions, many edges of the aluminum powder are raised, and each edge acts like a discharge terminal, so printing aluminum powder directly onto a nonwoven fabric yields a product with excellent energy storage and discharge functions. As a result, when the molded ceiling of this invention is adopted in a vehicle, turbulence in the air flowing inside and outside the roof panel of the vehicle body can be suppressed, resulting in improved driving stability and handling, and better handling. The evaluation of handling will be explained in detail later.

[0038] Furthermore, because the nonwoven fabric layer 45 contains fine spaces, it functions as an insulating layer. Therefore, when molding the vehicle's molded ceiling material 10 using a heated mold, the heat from the mold is less likely to be transferred to the non-permeable film 43 (non-permeable film layer 41). This prevents the non-permeable film 43, which has melted due to the heat transferred from the mold, from adhering to the mold along with the aluminum powder 52. Consequently, the time and cost required for maintenance such as cleaning the mold can be reduced.

[0039] (Examples) As an embodiment of the present invention, the following was created. A nonwoven fabric sheet 46 (nonwoven fabric layer 45) made of polyester resin fiber web treated with spunlace processing has a basis weight of 50 g / m². 2The nonwoven fabric sheet 46 (nonwoven fabric layer 45) is prepared by combining one side (inside the vehicle interior) of the nonwoven fabric sheet 46 (nonwoven fabric layer 45) with the non-permeable film layer 41, and then heating and fusing the two together to form the back layer 40. Next, the other side (outside the vehicle interior) of the nonwoven fabric sheet 46 of the back layer 40 is gravure printed with ink 50 containing aluminum powder 52. The ink 50 used is the LP Bio SX series manufactured by Toyo Ink Co., Ltd., and the type containing flaked aluminum as aluminum powder 52 was used. The amount of ink 50 applied (printed) to the nonwoven fabric sheet 46 is 12 g / m² in a wet state. 2 The aluminum powder 52 mainly consists of aluminum flakes, and is present in 0.48 g / m² of the wet ink 50. 2 It is included. This nonwoven fabric layer 45 is, for example, heated and dried to dry the ink 50 and bring it to a dry state.

[0040] A portion of the back layer 40 was cut out and designated as Sample A. The amount of ink 50 to be printed was 24 g / m² for Sample B. 2 Sample C is 34 g / m² 2 The rest was the same as Sample A.

[0041] Figures 3(A), 3(B), and 3(C) are micrographs (50x magnification) of the surface of the nonwoven fabric sheet 46 of the back layer 40 of samples A, B, and C.

[0042] In sample A shown in Figure 3(A), the white areas are fibers 47. The luminous, granular particles are aluminum powder 52. As can be seen from Figure 3(A), the aluminum powder 52 is dispersed and partially present among the fibers 47 of the nonwoven fabric sheet 46.

[0043] In sample B of Figure 3(B), the amount of aluminum powder 52 was increased compared to sample A of Figure 3(A), resulting in a greater presence of aluminum powder 52 that appears as a white, shiny substance.

[0044] In sample C in Figure 3(C), the amount of aluminum powder 52 was increased even further than in sample B in Figure 3(B), so a larger amount of the white, luminous aluminum powder 52 was observed.

[0045] If the amount of aluminum powder 52 in the ink 50 increases, the amount of aluminum powder 52 adhering to the surface of the fiber 47 increases, but it still adheres to the surface of the fiber 47 in a randomly dispersed state. Since the fibers 47 that are intertwined in various directions three-dimensionally form a surface with unevenness, when the ink 50 containing the aluminum powder 52 is gravure printed, it adheres randomly and partially to the convex and concave surfaces of the fiber 47. In particular, the ink 50 containing the aluminum powder 52 adheres to the convex surface rather than the concave surface.

[0046] In addition, when changing from the Wet state to the Dry state after applying the ink 50 to the non-woven fabric sheet 46, the application amount of the ink 50 is 12 g / m 2 to 2.6 g / m 2 in sample A, 24 g / m 2 to 5.3 g / m 2 in sample B, and 34 g / m 2 to 7.5 g / m 2 in sample C. It is considered that most of the ink components 51 in the ink 50 volatilize and disappear without adhering to the fibers 47 of the non-woven fabric sheet 46. In the present invention, it is considered that some of the aluminum powder 52 also flows without adhering to the fibers 47. However, since it is difficult to measure how much of the aluminum powder 52 adheres to the fibers 47 and how much does not adhere to the fibers 47, it is assumed that all of the aluminum powder 52 in the Wet state ink 50 adheres to the fibers 47.

[0047] In order to observe the surface of the non-woven fabric layer 45 in the back surface layer 40 in more detail, a spunlace non-woven fabric of PET resin was used. A sample D was prepared by intaglio printing no aluminum powder 52 on the surface of the non-woven fabric sheet 46 made of the spunlace non-woven fabric, and a sample E was prepared by intaglio printing aluminum powder 52 on the surface of the non-woven fabric sheet 46.

[0048] A part of the back surface layer 40 was cut out, and the surface of the non-woven fabric sheet 46 was observed with a scanning electron microscope (magnification: 1,000 times). FIG. 4(A) shows the observation result of the surface of sample D. Also, FIG. 4(B) shows the observation result of the surface of sample E.

[0049] In sample D of Figure 4(A), the fibers 47 of the nonwoven fabric sheet 46 are intertwined in various directions three-dimensionally, forming an uneven surface. In contrast, in sample E of Figure 4(B), the ink 50 containing aluminum powder 52 is partially and randomly attached to the surface of the intertwined fibers 47 that are oriented in various directions three-dimensionally. In particular, at the outermost surface of the fibers 47, where adjacent fibers 47 are close together, areas are observed where the ink 50 containing aluminum powder 52 is attached in a bridge-like manner. However, even at the outermost surface of the fibers 47, where adjacent fibers 47 are far apart, no bridge-like attachment is observed, and the surface of the fibers 47 is either thinly coated with ink 50 or aluminum powder 52, or almost completely unattached. Furthermore, most of the ink 50 and aluminum powder 52 are not attached to the surface of the fibers 47 located in recessed areas from the outermost surface. In other words, the amount of aluminum powder 52 attached to the concave surface is less than that attached to the convex surface. The aluminum powder 52 is dispersed and attached to the surface of the fibers, with a particularly large amount attached to the outermost surface. These aluminum powders temporarily store electricity and then discharge the stored charge. In other words, they can repeatedly store and discharge electricity. In particular, the fibers of the nonwoven fabric are intertwined in a three-dimensional, uneven manner, and since the aluminum powder adheres to the surface of these fibers, the aluminum powder does not align in the same direction in a planar manner, but rather adheres in various directions in three dimensions. Since some individual aluminum powder particles are oriented vertically, horizontally, or diagonally, the edges of the dispersed aluminum powder particles are exposed, functioning as if they were self-discharge terminals. Because there are many aluminum powder particles that function as self-discharge terminals, the molded ceiling of the embodiment of the present invention has excellent discharge properties.

[0050] As shown in Figure 5, for example, the aluminum powder adheres to or clings to the three-dimensional surface of the nonwoven fabric fibers, which are oriented in various directions. Therefore, the aluminum powder adheres in various directions, such as vertically, horizontally, and diagonally. Moreover, each aluminum powder particle is almost independent and separate, and each particle is not simply circular or elliptical, but rather has a flat shape with sharp edges, so these edges can function as discharge terminals.

[0051] (Peel strength) Samples A, B, and C, which are embodiments of the present invention, were prepared. Sample H, a comparative example (1), was also prepared for comparison with the embodiments of the present invention.

[0052] Sample H in Comparative Example 1 was prepared by bonding an aluminum-deposited film, in which aluminum powder was deposited onto a film, to a non-permeable film layer similar to that of the present invention.

[0053] Peel strength was measured using a Shimadzu Autograph AG-Xplus10KN, after holding the samples in a low-temperature chamber at -30°C ± 2°C for 2 hours. The strength (N) was then measured when peeling the samples at a tensile speed of 200 mm / min in this temperature atmosphere. The average of three values ​​was used for each sample.

[0054] The peel strengths were 122.7N for sample A of the present invention, 122.3N for sample B, 123.3N for sample C, and 51.6N for sample H of Comparative Example 1. The present invention clearly showed superior peel strength (peel resistance) compared to Comparative Example 1. This is because, in the present invention, in which aluminum powder 52 is attached to the surface of the nonwoven fabric sheet 46, when vehicle parts such as brackets and wire harnesses (not shown) are attached to the nonwoven fabric layer 45 with an adhesive such as hot melt, the excellent effect of making them difficult to peel off was achieved. This is thought to be because, in the case of samples A, B, and C of the present invention, the adhesive adheres to the fibers 47 of the nonwoven fabric layer 45.

[0055] On the other hand, in Sample H of Comparative Example 1, the aluminum vapor-deposited film was a flat plane, resulting in a more easily peeled-off surface compared to the present invention. Thus, if the surface is flat or a flat film, like the aluminum vapor-deposited film in Comparative Example 1, rather than having an uneven surface like the nonwoven fabric layer 45 of the present invention, it can be said that vehicle parts such as brackets and wire harnesses are relatively more likely to peel off when attached with adhesive.

[0056] Furthermore, in samples A, B, and C of the present invention, the impact noise was reduced compared to sample H. Although the detailed reasons are unclear, it is thought that the aluminum powder is dispersed and unevenly attached to and / or wrapped around the nonwoven fabric, thereby mitigating the impact noise or reducing reflected sound, and that the uneven surface of the nonwoven fabric is maintained even when the aluminum powder is printed on it, resulting in excellent sound insulation.

[0057] Furthermore, it is known that a vehicle body becomes positively charged with static electricity when in motion. This positive static electricity can cause the positively charged airflow to separate from the flow along the charged surface of the vehicle body, resulting in poor driving performance and handling stability. One possible solution is to neutralize and reduce the positive potential through self-discharge, which generates negative air ions in response to the positive potential. It is thought that significant results can be obtained by employing this self-discharge method on a molded ceiling that is positioned along the roof on the interior side of the roof and has a large surface area. For example, it is conceivable to attach metal pieces to almost the entire surface of the molded ceiling on the roof panel side. Specifically, the following methods can be considered: (a) attaching a film with aluminum powder vapor-deposited onto it, (b) attaching a film printed with ink containing aluminum powder, or (c) directly printing ink containing aluminum powder onto the nonwoven fabric that forms the surface of the molded ceiling on the roof panel side, as in the present invention. We investigated which of these three methods would be effective in improving handling stability.

[0058] The verification experiment uses a commonly used molded ceiling, so a detailed explanation will be omitted. A vehicle was prepared with a rigid polyurethane foam base layer, reinforcing layers made of glass fiber mats on both sides of the base layer, a surface layer consisting of tricot and soft polyurethane foam on the surface of one of the reinforcing layers, and a non-breathable membrane layer as the back layer. On this vehicle, the best approach would be to prepare and test (a) a film with aluminum powder vapor-deposited onto the surface of the non-breathable membrane layer, (b) a film with ink containing aluminum powder printed onto the surface of the non-breathable membrane layer, and (c) a non-woven fabric layer on the surface of the non-breathable membrane layer with ink containing aluminum powder directly printed onto the surface of this non-woven fabric layer, on almost the entire surface of the roof panel side of the molded ceiling. However, at present, as a simpler method, the experiment shown in Figure 6 was conducted. Figure 6 is a schematic cross-sectional view showing the molded ceiling 10 and the roof panel 2, with each sample S attached to the interior side of the molded ceiling with adhesive tape T. 3 is the reinforcement.

[0059] A 200mm x 220mm sample piece was attached to the interior side of the molded ceiling of a vehicle equipped with the above-mentioned molded ceiling, and the handling stability was sensory evaluated during driving. The samples were made from a portion of the above-mentioned molded ceiling, with a non-permeable membrane layer and spunlace nonwoven fabric as the back layer. Sample D1 was made without intaglio printing of aluminum powder on the outer surface of the nonwoven fabric, while Samples E1, E2, and E3 were made with intaglio printing of aluminum powder on the surface of the nonwoven fabric sheet. An example in which a film with vapor-deposited aluminum powder was laminated to the surface of only the non-permeable membrane layer without the nonwoven fabric sheet was made, and an example in which a film with ink containing aluminum powder was laminated to the surface of only the non-permeable membrane layer without the nonwoven fabric sheet was made. The aluminum ink content of Samples E1, E2, and E3 was 3g / m² each. 2 5g / m 2 9g / m 2 This is the case. When printing with this aluminum-containing ink, the print weight in the wet state is 12 g / m². 2 If it's that ink, then when converted to aluminum powder it would be 0.6g / m² 2 This means that samples E1, E2, and E3 each contain 0.6 g / m of aluminum powder. 2 1.0g / m2 1.8g / m 2 It includes.

[0060] Sample F1 was an aluminum vapor-deposited film prepared by forming a 0.05 μm aluminum vapor-deposited layer on a base film. Sample G1 used a film in which a coating containing flaky aluminum flakes and resin was gravure coated onto an OPET film, resulting in a film in which the flaky aluminum flakes were arranged parallel to the surface of the coating.

[0061] Then, as shown in Figure 6, each sample S was attached to the interior side of the molded ceiling 10 using adhesive tape T. The handling stability felt by the driver was evaluated when the vehicle was driven with each sample attached, and also when the vehicle was driven with some of the samples removed. The reason for conducting experiments with both the samples attached to the molded ceiling and partially removed was to confirm the difference between cases where there is airflow between the molded ceiling and the sample and cases where there is no airflow.

[0062] Figure 7 schematically illustrates the behavior of positive ions in each sample S (i.e., samples D1, E1, E2, E3, F1, G1) when driven with the tape attached and when driven with a portion of the tape removed. Although the actual accumulation and release of positive ions cannot be measured, it is hypothesized to occur as follows. As shown in Figure 7(A), when sample S is attached, positive ions accumulate on the surface of the molded ceiling side of sample S. There was no significant difference in this state among samples E1, E2, E3, F1, and G1. Notably, no accumulation of positive ions was observed in sample D1. When a portion of the adhesive tape T is removed, a gap is created between sample S and the molded ceiling, generating airflow. At this time, we observed whether or not the positive ions accumulated on the surface of sample S were released. Figure 7(B) shows samples E1, E2, and E3 of the present invention. As shown in Figure 7(B), it appears that a large amount of positive ions were released in all cases. On the other hand, Figure 7(C) shows samples F1 and G1. As shown in Figure 7(C), it appears that only a small amount of positive ions were released in samples F1 and G1.

[0063] Handling stability was evaluated using a five-point scale: "◎" (excellent), "〇" (good), "△" (slightly improved), "―" (no change), and "×" (worsened). The results are shown in Figure 8.

[0064] As shown in Figure 8, for samples E1, E2, and E3, the handling stability was "◎" or "〇" whether the sample was attached or partially peeled off. For samples F1 and G1, the handling stability was "〇" when the sample was attached, but "△" when partially peeled off. Furthermore, for sample D1, the handling stability was "-" whether it was attached or partially peeled off. Since sample D1 only has a nonwoven fabric on the surface and no metal fragments to discharge, there was no self-discharge, and the handling stability was the same as before.

[0065] Furthermore, the reason why the handling stability of samples F1 and G1 yielded these results is that when films coated with aluminum powder or films printed with ink containing aluminum powder are laminated together, the aluminum powder is arranged as a flat surface on the roof panel side of the molded ceiling. As a result, with such a film surface, the edge area where the discharge function of the aluminum pieces is active is almost entirely limited to the aluminum pieces around the edges of the sample sheet, resulting in a weak discharge function, and consequently, the handling stability was not as good as expected.

[0066] On the other hand, in samples E1, E2, and E3 of the present invention, as shown in Figure 5, aluminum powder is dispersed and independently attached to the surface of the three-dimensional fibers, and even in a planar view, the aluminum powder exists at intervals. Since the aluminum powder adheres to or clings to the uneven fibers that are entangled in the nonwoven fabric, the aluminum powder is dispersed and attached to the protruding parts of the uneven fibers and to the parts that are inclined and arranged three-dimensionally. In other words, since the aluminum powder is often dispersed and attached in a way that makes the edges stand out, we predict that discharge will occur actively from the edge parts.

[0067] As previously mentioned, when a film with aluminum powder vapor-deposited or a film printed with ink containing aluminum powder is laminated to the entire roof panel side of a molded ceiling, as previously mentioned, when vehicle parts such as brackets and wire harnesses (not shown) are attached to the nonwoven fabric layer 45 with an adhesive such as hot melt, they may peel off when exposed to harsh environments. In contrast, in the present invention, when vehicle parts such as brackets and wire harnesses (not shown) are attached to the nonwoven fabric layer 45 with an adhesive such as hot melt, the aluminum powder adheres to the uneven surface of the nonwoven fabric and, in some cases, clings to it, thus exhibiting the excellent effect of being difficult to peel off.

[0068] As described above, the present invention not only has the excellent function of preventing parts such as wire harnesses and brackets from peeling off when they are attached to the back side of the molded ceiling, but also has the excellent function of preventing parts from peeling off when parts such as wire harnesses and brackets are attached to the back side of the molded ceiling from peeling off, and in some cases has aluminum powder attached to the surface of the nonwoven fabric on the roof panel side of the molded ceiling, and in some cases has wrapped around it. At this time, the fibers of the nonwoven fabric are intertwined in a three-dimensional uneven state, and the aluminum powder is attached to the fibers in a three-dimensional uneven state according to the fibers of the nonwoven fabric. A large proportion of the individual aluminum powder particles are attached in a dispersed manner with sharp edges. Because these aluminum powder particles are dispersed, they have an excellent function of temporarily storing electricity, and because the individual aluminum powder particles are attached with sharp edges, they also have an excellent self-discharge function. Because the aluminum powder of the present invention repeatedly stores and discharges electricity, it can exert an excellent effect in suppressing the separation of positively charged airflow from the flow along the charged surface of the vehicle body, and thus can exert excellent functions in handling, maneuverability, and driving stability.

[0069] These results show that when aluminum powder is applied to the nonwoven fabric surface of the molded ceiling on the roof panel side, the molded ceiling is neutralized and statically discharged, lowering its potential, which in turn lowers the potential of the roof formed by the steel plate. In other words, by applying aluminum powder to the molded ceiling, the potential of the roof is indirectly lowered through the air layer between the molded ceiling and the roof. As a result, separation of airflow from the outer surface of the roof can be suppressed, thus preventing a decrease in downforce that pushes the vehicle down. Furthermore, when cornering or when subjected to crosswinds, separation of airflow in a direction inclined from the longitudinal direction of the vehicle can be suppressed, thus preventing changes in the aerodynamic characteristics in the yaw direction. As a result, handling stability and ride comfort can be improved.

[0070] Furthermore, although the above embodiment described an example in which a nonwoven fabric sheet 46 forming the nonwoven fabric layer 45 and a non-permeable film layer 41 are joined to form a back layer 40, and ink 50 containing aluminum powder 52 is printed on the back layer 40, it is also possible to print ink 50 containing aluminum powder 52 on the surface of the nonwoven fabric sheet 46 to form a nonwoven fabric layer 45 with aluminum powder 52 attached, and then join the surface of the nonwoven fabric layer 45 that does not have aluminum powder 52 printed on it with the non-permeable film layer 41 to form the back layer 40. [Industrial applicability]

[0071] The present invention is suitable for molded ceiling materials for vehicles and methods for manufacturing the same. [Explanation of symbols]

[0072] 1 vehicle 2 Roof Panels 10. Molded ceiling material for vehicles 20 Base material layer 21. First fiber reinforcement layer 22 Second Fiber Reinforcement Layer 30 Epidermal layer 32 Skin material 40 Back layer 41 Non-permeable membrane layer 43 Non-breathable film 45 Non-woven layer 46 Nonwoven fabric sheet 47 Fibers 50 inks 51 Ink Components 52 Aluminum powder

Claims

1. A panel-shaped molded ceiling material for vehicles, which is installed on the interior side of the roof panel of a vehicle, A base layer and A first fiber reinforcing layer provided on the vehicle interior side of the above base material layer, A second fiber reinforcement layer is provided on the roof panel side of the above-mentioned base material layer, The surface layer provided on the interior side of the first fiber reinforced layer, The second fiber reinforcement layer is provided on the roof panel side, and comprises a back surface layer. The above-mentioned back surface layer has, in order from the inside of the vehicle interior, a non-breathable film layer and a nonwoven fabric layer. The above nonwoven fabric layer is a molded ceiling material for vehicles, characterized in that aluminum is attached to its surface.

2. In the molded ceiling material for a vehicle according to claim 1, The above aluminum is aluminum powder. A molded ceiling material for vehicles, characterized in that the aluminum powder is dispersed and attached to the surface of the nonwoven fabric layer.

3. In the molded ceiling material for vehicles according to claim 2, The above-mentioned aluminum powder is characterized by originating from aluminum powder contained in ink, and is a molded ceiling material for vehicles.

4. In the method for manufacturing a molded ceiling material for a vehicle according to claim 2, The nonwoven fabric sheet forming the above nonwoven fabric layer is joined to the non-permeable film layer to form the back layer. The other side of the nonwoven fabric sheet is printed with the ink containing the aluminum powder. A method for manufacturing a molded ceiling material for a vehicle, characterized by stacking a surface material that forms the surface layer, a first glass fiber reinforcing material that forms the first fiber reinforcing layer, a core material that forms the base material layer, a second glass fiber reinforcing material that forms the second fiber reinforcing layer, and the back surface layer, then heating and compressing the layers to produce the molded ceiling material for a vehicle in which the surface layer, the first fiber reinforcing layer, the base material layer, the second fiber reinforcing layer, and the back surface layer are integrated.

5. In the method for manufacturing a molded ceiling material for a vehicle according to claim 2, The surface of the nonwoven fabric sheet is printed with ink containing the above aluminum powder to form the above nonwoven fabric layer to which the above aluminum powder is attached. The non-woven fabric layer is joined to the non-permeable film layer by joining the surface of the non-woven fabric layer on the side where the aluminum powder is not printed, thereby forming the back surface layer. A method for manufacturing a molded ceiling material for a vehicle, characterized by stacking a surface material that forms the surface layer, a first glass fiber reinforcing material that forms the first fiber reinforcing layer, a core material that forms the base material layer, a second glass fiber reinforcing material that forms the second fiber reinforcing layer, and the back surface layer, then heating and compressing the layers to produce the molded ceiling material for a vehicle in which the surface layer, the first fiber reinforcing layer, the base material layer, the second fiber reinforcing layer, and the back surface layer are integrated.

6. In the method for manufacturing a molded ceiling material for a vehicle according to claim 4 or 5, The above printing method is characterized by being intaglio printing, and is a method for manufacturing a molded ceiling material for vehicles.

7. In the method for manufacturing a molded ceiling material for a vehicle according to claim 6, The above-mentioned intaglio printing is characterized by gravure printing, and is a method for manufacturing a molded ceiling material for vehicles.

Images