Reinforcement board and method for manufacturing the same

Abstract

To provide a reinforcement board capable of improving heat insulation performance, and to provide a manufacturing method of the reinforcement board.SOLUTION: A reinforcement board 10 is bonded to a lower surface 91M of a roof panel 91 of a vehicle 90 to form a lamination structure of a resin foam layer 21. An upper recessed part 32 forming a gap S between the roof panel 91 and the reinforcement board 10 is formed on an upper surface of the reinforcement board 10. The reinforcement board 10 includes: a non-vent layer 70 laminated on the resin foam layer 21 from below; and a lower metal layer 23 contained in the non-vent layer 70.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] The present disclosure relates to a reinforcing board that is bonded to the underside of a vehicle roof panel and a method for manufacturing the same. [Background technology]

[0002] 2. Description of the Related Art Conventionally, reinforcing boards for reinforcing roof panels have been known that have a foamed resin layer and whose entire upper surface is bonded to the roof panel (see, for example, Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2008-179343 A (paragraph

[0021] , figures 3 and 4) Summary of the Invention [Problem to be solved by the invention]

[0004] There is a demand for improved thermal insulation performance compared to conventional reinforced boards. [Means for solving the problem]

[0005] In order to solve the above problems, First aspect of the invention is a reinforcing board that is bonded to the underside of a roof panel of a vehicle and has a laminated structure including a foamed resin layer, the upper surface of which has an upper recess that forms a gap between the roof panel and the reinforcing board, the reinforcing board having a non-air-permeable layer laminated from below on the foamed resin layer, and a first metal layer included in the non-air-permeable layer.

[0006] Second aspect of the invention The non-breathable layer includes the first metal layer which is non-breathable, or includes a structure in which the first metal layer is laminated on a non-breathable base layer by metal spraying or metal vapor deposition. First aspect 2. The reinforcing board according to claim 1 .

[0007] Third aspect of the invention has a second metal layer laminated on the foamed resin layer from above, First or second aspect 2. The reinforcing board according to claim 1 .

[0008] Fourth aspect of the invention The second metal layer is a heat reflective layer that reflects radiant heat from the roof panel. Third aspect 2. The reinforcing board according to claim 1 .

[0009] Fifth aspect of the invention has an upper contact portion that is made up of a portion of the upper surface of the reinforcing board other than the upper recess and that is in close contact with the roof panel, and a proportion of the second metal layer provided on the inner surface of the upper recess is greater than a proportion of the second metal layer provided on the surface of the upper contact portion. Third or fourth aspect 2. The reinforcing board according to claim 1 .

[0010] Sixth aspect of the invention the second metal layer is provided only on the inner surface of the upper recess, Any one of the third to fifth aspects 2. The reinforcing board according to claim 1 .

[0011] Seventh aspect of the invention a face material having air permeability is disposed between the foamed resin layer and the second metal layer, Any one of the third to sixth aspects 2. The reinforcing board according to claim 1 .

[0012] Eighth aspect of the invention The depth of the upper recess is 2 mm or more. Any one of the first to seventh aspects 2. The reinforcing board according to claim 1 .

[0013] Ninth aspect of the invention The lower surface of the reinforcing board is substantially flat with no protrusions or recesses. Any one of the first to eighth aspects 2. The reinforcing board according to claim 1 .

[0014] Tenth aspect of the invention is a portion of the upper surface of the reinforcing board other than the upper recess, has an upper contact portion that is in close contact with the roof panel, and the upper contact portion has a lattice shape in a plan view. Any one of the first to ninth aspects 2. The reinforcing board according to claim 1 .

[0015] The eleventh aspect of the invention is any one of the third to seventh aspects. The method for manufacturing the reinforcing board described in the above item 1, further comprising the steps of: providing a molding recess at a rear surface of one of a pair of split dies that molds the upper surface of the reinforcing board by pressing, the molding recess forming an upper contact portion of the reinforcing board that is in close contact with the roof panel; forming a crack starting point portion that serves as a starting point for cracking the film body in a film body that is made of a non-breathable metal foil as the second metal layer, or a non-breathable base layer with a metal sprayed layer or metal vapor deposition layer as the second metal layer laminated thereon; and, when placing the film body on a board material including the foamed resin layer during the pressing between the pair of split dies, placing the film body closer to the one of the split dies than the board material, and overlapping the molding recess and the crack starting point portion.

[0016] The twelfth aspect of the invention is any one of the third to seventh aspects. This is a method for manufacturing a reinforced board described in the above, which includes forming an upper surface of a board material including the foamed resin layer into a three-dimensional shape, and then spraying a metal onto the upper surface of the board material to form the second metal layer having breathability.

[0017] The thirteenth aspect of the present invention is any one of the third to sixth aspects. This is a method for manufacturing a reinforcing board described in the above, in which the second metal layer is laminated onto a face material by spraying metal onto the face material, and the face material and the second metal layer are laminated onto the foamed resin layer from above, and then the laminate is pressed with a pair of split molds to form the reinforcing board.

[0018] The 14th aspect of the invention is the 13th aspect This is a method for manufacturing a reinforcing board described in the above, in which one of the pair of split dies that forms the upper surface of the reinforcing board is provided with a forming protrusion that forms the upper recess of the reinforcing board, and when forming the second metal layer, the metal is sprayed only onto the portion of the upper surface of the face material that faces the forming protrusion of the one of the split dies during the press. Effect of the Invention

[0019] First aspect of the invention In the reinforcing board, the upper recess forms a gap between the roof panel and the reinforcing board, which makes it possible to improve the heat insulating performance and also to exhibit heat shielding performance against radiant heat from the roof panel. In addition, by providing an impermeable layer, it becomes possible to further improve the heat insulating performance of the reinforcing board. In addition, by having an impermeable layer, it becomes possible to prevent the adhesive binder used for lamination from seeping out from the outer surface of the impermeable layer side (lower side) when manufacturing the reinforcing board by press molding, for example, and it becomes possible to prevent the binder from adhering to the molding die. In addition, by providing a first metal layer, it becomes possible to further improve the heat insulating performance of the reinforcing board. In addition, the impermeable layer may include a first metal layer that is impermeable, or may include a structure in which the first metal layer is laminated on a non-permeable base layer by metal spraying or metal vapor deposition ( Second aspect of the invention ).

[0020] Third aspect of the invention In this embodiment, metal layers are disposed above and below the foamed resin layer, so that the heat insulating performance of the reinforcing board can be further improved.

[0021] Fourth aspect of the invention In this case, the second metal layer laminated from above on the foamed resin layer makes it possible to reflect radiant heat from the vehicle roof panel, thereby improving the heat-shielding performance.

[0022] Fifth aspect of the invention In this case, the proportion of the second metal layer provided on the inner surface of the upper recess is greater than the proportion of the second metal layer provided on the surface of the upper contact portion. In other words, the proportion of the second metal layer provided on the upper contact portion that contacts the roof panel is smaller than that on the upper recess that does not contact the roof panel. This makes it possible to prevent heat from the roof panel from being transmitted through the second metal layer to the reinforcing board (particularly the top side of the reinforcing board). This can further improve the heat insulating performance of the reinforcing board. It is preferable that the second metal layer is provided only on the inner surface of the upper recess ( Sixth aspect of the invention). The depth of the upper recess is preferably 2 mm or more. Eighth aspect of the invention ).

[0023] Seventh aspect of the invention In the above, since a face material is disposed between the foamed resin layer and the second metal layer, it is possible to improve the rigidity of the reinforcement board. Furthermore, by having the face material, it is possible to prevent the adhesive binder from seeping out from the outer surface on the second metal layer side and adhering to the molding die when the reinforcement board is manufactured by press molding, for example. Moreover, since the face material has air permeability, it is possible to improve the sound absorption of the reinforcement board.

[0024] The lower surface of the reinforcing board may have a shape provided with a protrusion or a recess, or may have a substantially flat shape without any protrusion or recess. (Ninth aspect of the invention).

[0025] Tenth aspect of the invention By making the upper adhesion portion lattice-shaped when viewed in a plane, it is possible to improve the rigidity of the reinforcing board, and by adhering such an upper adhesion portion to the roof panel, the reinforcing performance of the roof panel is improved.

[0026] Eleventh aspect of the invention In the method, a film body made of air-impermeable metal foil or a film body made by spraying or vapor-depositing a metal on an air-impermeable base layer is placed on a board material having a foamed resin layer, and then pressed with a pair of split dies to form a reinforced board. Here, when the film body and the board material are arranged between the pair of split dies, the cracking starting point of the film body is placed on a molding recess in one of the split dies, which forms the upper adhesive part of the reinforced board at its rear surface. By pressing in this arrangement, the film body is split from the cracking starting point, and the foamed resin layer is pushed out (relatively protruded) from the split to the upper surface side of the reinforced board in the molding recess to form the upper adhesive part. This makes it easier to form a second metal layer in the upper recess on the upper surface of the reinforced board than on the upper surface (top surface) of the upper adhesive part.

[0027] Twelfth aspect of the inventionIn this method, the top surface of the board material including the foamed resin layer is formed into a three-dimensional shape, and then a metal is sprayed onto the top surface of the board material to form a second metal layer. By forming the second metal layer by metal spraying in this manner, it becomes easy to provide the second metal layer with breathability. In addition, since the top surface of the board material is formed into a three-dimensional shape before the second metal layer is formed, it becomes easy to form the second metal layer in a desired location on the top surface of the reinforcing board (for example, the inner surface of the upper recess). Note that the second metal layer may be laminated onto the board material, and then they may be press-molded ( Thirteenth aspect of the invention ).

[0028] Thirteenth aspect of the invention In the present invention, the second metal layer is formed by metal spraying, so it is easy to make the second metal layer breathable. Here, in a configuration in which the second metal layer is breathable, if a binder is used for adhesion, there is a risk that the binder will seep out to the outside through the second metal layer. Therefore, when the reinforcing board is manufactured by press molding, there is a risk that the binder will adhere to the molding die. In response to this, Aspects In the case of the molded article, the second metal layer is formed by metal spraying, and the second metal layer can be formed by depositing a large number of metal particles in multiple layers, which makes it possible to suppress the seepage of the binder through the second metal layer. This makes it possible to suppress the adhesion of the binder to the molding die. In addition, when the binder is used in this manner, the surface material can also suppress the seepage of the binder from the second metal layer side, and even if the second metal layer is configured to be breathable, the binder can be suppressed from leaking out to the outside.

[0029] Fourteenth aspect of the invention This makes it possible to form the second metal layer only on the inner surface of the upper recess of the reinforcing board. [Brief description of the drawings]

[0030] [Figure 1] (A) is a perspective view of a vehicle to which a reinforcing board according to an embodiment of the present disclosure is attached, and (B) is a cross-sectional view of a ceiling portion of the vehicle. [Diagram 2] Cross-section of roof panel and reinforcing board [Diagram 3]Partially cutaway perspective view of the reinforcement board [Figure 4] A partially cutaway perspective view of a metal foil laminated on a foam sheet. [Diagram 5] Cross-sectional view of the laminate being set between the upper and lower dies [Figure 6] Cross-section of the reinforcement board formed by hot pressing [Figure 7] Table showing each experimental example [Figure 8] Cross-section of the experimental setup [Figure 9] FIG. 1A is a partially cutaway perspective view of a reinforcing board according to another embodiment; FIG. 1B is a partially cutaway perspective view of a group of sheets set between an upper mold and a lower mold; [Figure 10] 11 is a cross-sectional view of a reinforcing board according to another embodiment. [Figure 11] 11 is a cross-sectional view of a reinforcing board according to another embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0031] As shown in Fig. 1(A), the reinforcing board 10 of this embodiment is attached to a roof panel 91 of a vehicle 90. Specifically, as shown in Fig. 1(B), the reinforcing board 10 is disposed between the roof panel 91 and an interior molded ceiling 92, and is attached to a lower surface 91M (surface facing the inside of the vehicle) of the roof panel 91 via an adhesive 93 (see Fig. 2). The roof panel 91 is curved so that the central portion bulges outward (upward) of the vehicle 90, and the lower surface 91M of the roof panel 91 is a curved concave surface. The reinforcing board 10 is shaped to fit the lower surface 91M of the roof panel 91.

[0032] 2, the reinforcing board 10 has a laminated structure. Specifically, the reinforcing board 10 has a foamed resin layer 21 and a pair of reinforcing layers 22, 22 bonded to both the front and back (top and bottom) surfaces of the foamed resin layer 21. Each reinforcing layer 22 is made of, for example, a nonmetallic fiber sheet. Each reinforcing layer 22 is bonded to the foamed resin layer 21 by, for example, a binder.

[0033] The reinforcing board 10 is provided with a metal layer. Specifically, a lower metal layer 23 is laminated from the lower side (vehicle compartment side) on the foamed resin layer 21 via the reinforcing layer 22, and an upper metal layer 24 is laminated from the upper side (roof panel side) on the foamed resin layer 21 via the reinforcing layer 22. That is, the lower metal layer 23 and the upper metal layer 24 are laminated from the opposite side (outside) of the foamed resin layer 21 with respect to each reinforcing layer 22. In this embodiment, a surface material 25 is further provided between the upper reinforcing layer 22 and the upper metal layer 24. In this embodiment, the lower metal layer 23 and the upper metal layer 24 correspond to the "first metal layer" and the "second metal layer" described in the claims, respectively.

[0034] The reinforcing layers 22, the metal layers 23 and 24, and the surface material 25 are integrated together, for example, by a binder. The above-mentioned binder that bonds the foamed resin layer 21 and the reinforcing layers 22 may be the same as the binder that bonds the reinforcing layers 22, the lower metal layer 23, and the surface material 25. For example, in this case, the binder may be soaked into the reinforcing layer 22. Furthermore, in the case where the surface material 25 has air permeability, the surface material 25 and the upper metal layer 24 may be bonded together by the binder. Furthermore, the binder may be soaked into the foamed resin layer 21.

[0035] In this embodiment, the lower metal layer 23 constitutes the bottom layer of the reinforcing board 10, but one or more layers (e.g., a resin layer, a fiber layer, etc.) may be laminated below the lower metal layer 23. In this embodiment, the lower metal layer 23 is made of a non-air-permeable metal foil. That is, the reinforcing board 10 is configured such that the foamed resin layer 21 is laminated with a non-air-permeable layer 70 including the lower metal layer 23 from the bottom. The lower metal layer 23 may be, for example, a metal vapor deposition layer formed by metal vapor deposition, or a metal sprayed layer formed by metal spraying. In these cases, the base layer on which the metal vapor deposition layer or the metal sprayed layer is laminated by performing metal vapor deposition or metal spraying may be made non-air-permeable. This allows the non-air-permeable layer 70 including the base layer and the lower metal layer 23 to be formed. The base layer may have a single layer structure or a laminated structure consisting of multiple layers. The base layer may be, for example, a resin layer or a fiber layer. The base layer may also be a surface material 25. The base layer may be disposed below the lower metal layer 23, or may be disposed above it (i.e., between the lower metal layer 23 and the reinforcing layer 22). When the lower metal layer 23 is made of, for example, a non-breathable metal foil, laminating the lower metal layer 23 on a base layer made of a non-breathable sheet makes it possible to improve the heat insulating performance of the reinforcing board 10 while reducing the thickness of the metal foil.

[0036] The upper metal layer 24 is a heat reflecting layer that reflects radiant heat (specifically, electromagnetic waves such as infrared rays) from the roof panel 91. In this embodiment, the upper metal layer 24 constitutes the uppermost layer of the reinforcing board 10, but for example, a transparent layer or the like may be laminated on the upper side of the upper metal layer 24. With this configuration, the heat from the roof panel 91 can be reflected by the upper metal layer 24 by transmitting the heat through the transparent layer. The upper metal layer 24 may be either non-permeable or permeable. In addition, the upper metal layer 24 may be laminated and integrated with the foamed resin layer 21, the reinforcing layer 22, and the face material 25 when the reinforcing board 10 is molded, or may be formed by post-processing such as metal spraying after the foamed resin layer 21, the reinforcing layer 22, and the face material 25 are molded and laminated and integrated.

[0037] As shown in FIG. 2 and FIG. 3, an upper recess 32 is formed on the upper surface of the reinforcing board 10. In this embodiment, a plurality of upper recesses 32 are provided, and the bottom surface of the upper recess 32 is substantially flat. In addition, the portion of the upper surface of the reinforcing board 10 other than the plurality of upper recesses 32, in other words, the top surface portion 30M which is the protruding tip surface of the upper protrusion 30 protruding upward from the bottom surface of the upper recess 32, is in close contact with the roof panel 91. Then, the top surface portion 30M is bonded to the roof panel 91, whereby the reinforcing board 10 is bonded to the roof panel 91, and at this time, a gap S is formed between the roof panel 91 and the reinforcing board 10 by the upper recess 32. In this embodiment, the top surface portion 30M corresponds to the "upper contact portion" described in the claims.

[0038] In this embodiment, the top surface portion 30M has a shape corresponding to the lower surface 91M of the roof panel 91, and the entire top surface portion 30M is adhered to the lower surface 91M of the roof panel 91 via the adhesive 93 so as to be in close contact with no gaps (see FIG. 2). That is, in this embodiment, the adhesive 93 is laminated over the entire top surface portion 30M. In this embodiment, the lower surface of the reinforcing board 10 has a substantially flat shape with no protrusions or recesses. In other words, the reinforcing board 10 of this embodiment has a shape in which an upper protrusion 30 having the top surface portion 30M on its upper end surface is provided on a plate-shaped board main body portion 11.

[0039] In this embodiment, as shown in Fig. 3, the top surface portion 30M (upper protrusion 30) has a lattice shape in a plan view. Specifically, in this embodiment, the upper protrusion 30 has a shape in which a plurality of substantially parallel bank-like protrusions 31 are arranged to extend in the front-rear direction and the vehicle width direction of the vehicle 90 and intersect with each other. Since the upper protrusion 30 has a lattice shape, it is possible to improve the rigidity of the reinforcing board 10 in each extension direction of the intersecting protrusions 31. In addition, by bonding such a top surface portion 30M to the roof panel 91, the reinforcing performance of the roof panel 91 is improved.

[0040] In this embodiment, as described below, the foamed resin layer 21 is compressed from above in the thickness direction to form a plurality of upper recesses 32. As a result, the portions of the foamed resin layer 21 that do not overlap with the upper recesses 32 in the thickness direction become relatively thick, and form the above-mentioned top surface portion 30M on the upper surface. The portions of the foamed resin layer 21 that overlap with the top surface portion 30M in the thickness direction have a lower apparent density than the portions that overlap with the upper recesses 32, and are, for example, hardly compressed.

[0041] The depth of the upper recess 32 (i.e., the amount of protrusion of the upper protrusion 30) is preferably 2 mm or more, more preferably 5 mm or more, and even more preferably 7 mm or more. By making the upper protrusion 30 2 mm or more, for example, even when the vehicle vibrates, it becomes easy to secure a gap between the reinforcing board 10 and the roof panel 91, and heat transfer due to contact from the roof panel 91 to the reinforcing board 10 can be suppressed. The thickness of the board main body 11 (the distance between the lower surface of the reinforcing board 10 and the bottom surface of the upper recess 32) is preferably 3 to 20 mm. Here, in the example of this embodiment, the depth of the upper recess 32 (the amount of protrusion of the upper protrusion 30) is 2 mm or more, which is a sufficiently large dimension compared to the thickness of the adhesive 93. The thickness of a general adhesive 93 is 0.5 mm or less, and with a gap of this size, the distance between the roof panel 91 and the reinforcing board 10 becomes close, and therefore the gap is insufficient for imparting heat shielding performance to the reinforcing board 10.

[0042] In this embodiment, the proportion of the upper metal layer 24 provided on the inner surface of the upper recess 32 is greater than the proportion of the upper metal layer 24 provided on the surface of the top surface portion 30M. Specifically, in this embodiment, as shown in Figs. 2 and 3, the upper metal layer 24 is provided only in the upper recess 32, and is not provided on the top surface portion 30M. The upper metal layer 24 is disposed on the bottom surface of the upper recess 32 (the entire bottom surface in this embodiment), and is disposed with a gap S between it and the roof panel 91 without being in close contact with the roof panel 91. Therefore, in this embodiment, the upper protrusion 30 is composed of the foamed resin layer 21, the reinforcing layer 22 above it, and the surface material 25, which are parts that protrude above the upper metal layer 24. In the upper protrusion 30, the upper surface material 25 is exposed on the top surface of the reinforcing board 10 and is bonded to the roof panel 91 via an adhesive 93 (i.e., it constitutes the top surface portion 30M). The upper metal layer 24 may be provided only on a part of the bottom surface of the upper recess 32, but is preferably provided on the entire bottom surface of the upper recess 32. Also, the upper metal layer 24 may be provided on the side surface of the upper recess 32 (the side surface of the upper protrusion 30).

[0043] The foamed resin layer 21, the reinforcing layers 22, the metal layers 23 and 24, and the face material 25 of the reinforcing board 10 are detailed below.

[0044] The foamed resin layer 21 can be made of polyurethane foam, olefin resin foam such as polyethylene resin, etc., and is preferably polyurethane foam. As the polyurethane foam, rigid polyurethane foam, semi-rigid polyurethane foam, soft polyurethane foam, etc. can be used, and semi-rigid polyurethane foam, which is lightweight and has high rigidity, is preferable. In addition, the foamed resin layer 21 may have an open cell structure or a closed cell structure, but from the viewpoint of ease of shaping, it is preferable that it has an open cell structure.

[0045] The reinforcing layer 22 can be composed of, for example, a sheet of glass fiber, polyester fiber, polyamide fiber, acrylic fiber, vinylon fiber, carbon fiber, natural fiber (e.g., cellulose nanofiber), Zylon (registered trademark), or the like. The fibers constituting the reinforcing layer 22 may be in the form of woven fabric, knitted fabric, nonwoven fabric, or the like. Among these, a glass fiber sheet is preferred from the viewpoint of the reinforcing performance and vibration damping performance of the reinforcing board 10, and a glass mat (particularly a chopped strand mat) is more preferred. The basis weight of the reinforcing layer 22 is set to 400 g / m2 from the viewpoints of formability (particularly the formability of the upper recess 32 and the upper protrusion 30) and weight reduction. 2 From the viewpoint of reinforcing performance, the weight per unit area of ​​the reinforcing layer 22 is preferably 60 g / m 2 The above is preferred.

[0046] As described above, the lower metal layer 23 may be, for example, a non-breathable metal foil, or a metal vapor deposition layer or metal spray layer attached to a non-breathable base layer. Examples of the metal foil include aluminum foil and copper foil, and the thickness thereof is preferably 10 μm or more from the viewpoints of heat insulation performance, sound insulation performance, formability, etc., and is preferably 200 μm or less from the viewpoint of weight reduction. Examples of the base layer include a non-breathable sheet of a thermoplastic resin such as a polyethylene resin. The thickness of the base layer is preferably 10 μm or more from the viewpoints of heat insulation performance, sound insulation performance, formability, etc., and is preferably 200 μm or less from the viewpoint of weight reduction. The basis weight of the metal vapor deposition layer or metal spray layer is 50 g / m from the viewpoints of heat insulation performance and sound insulation performance. 2 More than 300 g / m is preferable, and from the viewpoint of weight reduction, 2 The following is preferable. Here, examples of metals constituting the metal vapor deposition layer or metal sprayed layer include aluminum, zinc, copper, etc., and these metals may be used alone or in combination (for example, alloys of these metals may be used). Note that the non-breathable layer 70 may be configured to include a breathable metal foil and a breathable layer.

[0047] The upper metal layer 24 may be either non-breathable or breathable. When the upper metal layer 24 is non-breathable, the heat insulating performance and sound insulation performance can be further improved, and when the upper metal layer 24 is breathable, sound from the roof panel 91 side can be absorbed. An example of the non-breathable upper metal layer 24 is metal foil. Also, an example of the breathable upper metal layer 24 is a metal vapor deposition layer formed by metal vapor deposition, a metal sprayed layer formed by metal spraying, a breathable metal foil (for example, one having a large number of through holes), and the like. As the metal foil, the same as the example of the metal foil constituting the lower metal layer 23 can be used.

[0048] The facing material 25 may be either breathable or non-breathable. Examples of the facing material 25 include breathable sheets such as nonwoven fabrics, and the weight per unit area is preferably 70 g / m from the viewpoints of formability and the barrier properties of the binder (bleed-out prevention properties). 2 More than 300 g / m is preferable, and from the viewpoint of weight reduction, 2 The following is preferable: When manufacturing the reinforcing board 10, in the case where a sheet in which the face material 25 and the upper metal layer 24 are integrally formed in advance is used (for example, in the case where a sheet in which the upper metal layer 24 is formed on the face material 25 by metal vapor deposition or metal spraying is used), examples of the face material 25 include a breathable sheet such as a nonwoven fabric and a non-breathable sheet of a thermoplastic resin such as a polyethylene resin.

[0049] The reinforcing board 10 is manufactured, for example, as follows. To manufacture the reinforcing board 10, first, a plurality of sheets are prepared. Specifically, as shown in FIG. 4, in this embodiment, a foamed sheet 21S, for example, rectangular in shape, made of semi-rigid polyurethane foam and constituting the foamed resin layer 21, a fiber sheet 22S, which is a glass fiber sheet constituting the reinforcing layer 22, a pair of membranes 23S, 24S, for example, made of non-breathable metal foil and constituting the lower metal layer 23 and the upper metal layer 24, and a face material 25 made of nonwoven fabric are prepared. A thermosetting resin binder is applied to the foamed sheet 21S and the fiber sheet 22S and is allowed to soak into them. The foamed sheet 21S is made of a material having an apparent density of 10 to 80 kg / m. 3Preferably, the thickness is 5 to 30 mm. At least one of the membranes 23S, 24S may be made of a sheet in which a metal sprayed layer or a metal vapor deposition layer is laminated on an air-impermeable base layer.

[0050] Here, as shown in FIG. 4, the film 24S, which is one of the pair of films 23S and 24S and constitutes the upper metal layer 24, is formed with a cleavage starting point 40 that is a starting point for cleavage of the film 24S. In this embodiment, the cleavage starting point 40 is in a lattice shape (shown by a broken line in FIG. 4). The cleavage starting point 40 is formed by, for example, crossing broken line portions 42 formed by a plurality of cuts 41 arranged in a straight line across the film 24S. In detail, the cleavage starting point 40 is formed by crossing a plurality of broken line portions 42 that extend substantially parallel to the long side direction of the rectangular film 24S and are arranged at substantially equal intervals, and a plurality of broken line portions 42 that extend substantially parallel to the short side direction of the film 24S and are arranged at substantially equal intervals. The intervals between these broken line portions 42 are set so that the cleavage starting point 40 is arranged to overlap a molding recess 51U of an upper mold 51 described below. The slit 41 of the broken line portion 42 is, for example, slit-shaped, and the broken line portion 42 extends in the extension direction of the slit 41.

[0051] FIG. 5 shows a pair of split dies for forming the reinforcing board 10. The molding surface 51M of the upper die 51, which is one of the split dies, is provided with a molding protrusion 51T for forming the upper recess 32. In other words, the molding surface 51M other than the protruding tip surface of the molding protrusion 51T is a molding recess 51U for forming the upper protrusion 30. The molding recess 51U is lattice-shaped. In detail, the inner surface of the molding recess 51U has a shape corresponding to the lower surface 91M of the roof panel 91 (a shape that is in close contact with the lower surface 91M) and forms the top surface portion 30M. In this embodiment, the molding surface 52M of the lower die 52, which is the other split die of the pair of split dies, has a substantially flat shape without any protrusions or recesses. In this embodiment, the molding surfaces 51M, 52M of the upper die 51 and the lower die 52 are generally shaped to conform to the lower surface 91M of the roof panel 91.

[0052] Then, the fiber sheets 22S are laid on both the front and back sides of the foamed sheet 21S, and the metal foil films 23S and 24S are laid on each of the fiber sheets 22S from the outside. At this time, the face material 25 is placed between the fiber sheet 22S and the film 24S. Then, the board-shaped laminate 20S thus laminated is sandwiched between the upper mold 51 and the lower mold 52 with the film 24S side facing the upper mold 51, and is hot-pressed. At this time, the film 24S is laid so that the cleavage starting point 40 faces the molding recess 51U of the upper mold 51 (in detail, the film 24S is placed so that the cleavage starting point 40 fits within the molding recess 51U when viewed from this facing direction). Then, the foamed resin layer 21, each reinforcing layer 22, the lower metal layer 23, and the upper metal layer 24 are formed by the hot press, and these and the face material 25 are bonded by the binder. At this time, one of the membrane bodies 24S is torn apart starting from the tearing origin part 40, and the foamed resin layer 21 and the reinforcing layer 22 and the face material 25 laminated thereon protrude (protrude relatively) from the tear 43 into the molding recess 51U, and the protruding part forms the upper protrusion 30 (top surface part 30M) (see FIG. 6). At the same time, the upper recess 32 is also formed. In detail, when the upper mold 51 is brought close to the lower mold 52, the molding protrusion 51T of the molding surface 51M of the upper mold 51 and the molding surface 52M of the lower mold 52 compress the laminate 20S (particularly the foamed sheet 21S), and the part of the membrane body 24S facing the molding protrusion 51T is pressed downward. On the other hand, the portion of the laminate 20S (particularly the foamed sheet 21S) facing the rear surface of the molded recess 51U is less compressed (e.g., hardly compressed) than the portion of the laminate 20S (particularly the foamed sheet 21S) facing the molded protrusion 51T. Therefore, the portion of the film 24S facing the rear surface of the molded recess 51U is held on the upper side by the elastic force of the foamed sheet 21S. As a result, the film 24S is stretched, and the film 24S is torn at the tearing starting point portion 40 where the strength of the film 24S is the weakest. Then, the foamed sheet 21S (specifically, the face material 25 and the upper reinforcing layer 22 as well) pops out from the tear 43. As a result, it becomes easier to form the upper metal layer 24 in the upper recess 32 on the upper surface of the reinforcing board 10 than in the top surface portion 30M, and in the example of this embodiment, the upper metal layer 24 is formed only in the upper recess 32.In the manufacturing method of the reinforcing board 10 of this embodiment, only the membrane 24S is cleaved in the laminate 20S. Furthermore, the laminate 20S is molded into a shape conforming to the lower surface 91M of the roof panel 91 by hot pressing, and the board main body 11 is also formed. In this manner, the reinforcing board 10 is obtained. The upper mold 51 and the lower mold 52 may be reversed upside down, and the membrane 24S of the laminate 20S may be placed on the lower side. In this embodiment, the laminate 20S in which the foamed sheet 21S, the pair of fiber sheets 22S, and the face material 25 are layered corresponds to the "board material" described in the claims.

[0053] In the reinforcing board 10 of this embodiment, the upper recess 32 forms a sufficient gap S between the roof panel 91 and the reinforcing board 10, so that it is possible to improve the heat insulating performance and also to exhibit heat shielding performance against radiant heat from the roof panel 91. In addition, by providing the non-air-permeable layer 70, it is possible to further improve the heat insulating performance of the reinforcing board 10. In addition, by having the non-air-permeable layer 70, when the reinforcing board 10 is manufactured by press molding, it is possible to prevent the adhesive binder from seeping out from the outer surface of the non-air-permeable layer 70 side (lower side), and it is possible to prevent the binder from adhering to the split mold (the lower mold 52 in the example of this embodiment). In addition, by providing the lower metal layer 23, it is possible to further improve the heat insulating performance of the reinforcing board 10. Moreover, since the metal layers 23 and 24 are arranged above and below the foamed resin layer 21, it is possible to further improve the heat insulating performance of the reinforcing board 10.

[0054] In this embodiment, the upper metal layer 24 laminated from above on the foamed resin layer 21 can reflect radiant heat from the roof panel 91 of the vehicle 90, and the heat shielding performance can be improved. In addition, in this embodiment, the proportion of the upper metal layer 24 provided on the inner surface of the upper recess 32 is greater than the proportion of the upper metal layer 24 provided on the surface of the top surface portion 30M. That is, the proportion of the upper metal layer 24 provided on the top surface portion 30M that contacts the roof panel 91 is smaller than that of the upper recess 32 that does not contact the roof panel 91. Therefore, it is possible to reduce the transmission of heat from the roof panel 91 to the reinforcing board 10 (particularly the upper surface side of the reinforcing board 10) through the upper metal layer 24. This can further improve the heat insulating performance of the reinforcing board. In addition, it is preferable that the upper metal layer 24 is provided only on the inner surface of the upper recess 32. In this configuration, the upper metal layer 24 is not provided on the portion (top surface portion 30M) of the reinforcing board 10 that contacts the roof panel, so that it is possible to prevent the heat of the roof panel 91 from being transferred to the reinforcing board 10 itself through the upper metal layer 24, which has a higher thermal conductivity than the face material 25. This prevents the reinforcing board 10 itself from being heated and accumulating heat, and the heat insulating performance of the reinforcing board 10 can be further improved. In addition, since the face material 25 is disposed between the foamed resin layer 21 and the upper metal layer 24, it is possible to improve the rigidity of the reinforcing board 10. Furthermore, by having the face material 25, it is possible to prevent the adhesive binder from seeping out from the outer surface on the upper metal layer 24 side and adhering to the split mold (upper mold 51) when the reinforcing board 10 is manufactured by press molding. Moreover, since the face material 25 has air permeability, it is possible to improve the sound absorbing property of the reinforcing board 10.

[0055] In the manufacturing method of the reinforcing board 10 of this embodiment, the film 24S made of a metal foil or a laminated sheet including a metal layer is placed on the surface material 25 that is placed on the foamed sheet 21S from above, and they are hot-pressed with the upper mold 51 and the lower mold 52 to form the reinforcing board 10. Here, when the film 24S, the surface material 25, the foamed sheet 21S, etc. are arranged between the upper mold 51 and the lower mold 52, the cleavage starting point 40 of the film 24S is placed on the molding recess 51U in the upper mold 51 for forming the upper protrusion 30. By performing hot pressing in this arrangement, the film 24S is cleaved starting from the cleavage starting point 40, and the foamed resin layer 21 (foamed sheet 21S) is relatively protruded from the crack 43 in the molding recess 51U to form the top surface 30M (upper protrusion 30). This makes it easier to form the upper metal layer 24 in the upper recess 32 on the upper surface of the reinforcing board 10 than on the top surface 30M, and makes it possible to form the upper metal layer 24 only on the portion of the reinforcing board 10 excluding the top surface 30M (only in the upper recess 32). Furthermore, it is also possible to form the upper metal layer 24 only on the bottom surface of the upper recess 32. Furthermore, according to the manufacturing method for the reinforcing board 10 of this embodiment, when the film body 24S is torn, the elastic force of the foamed sheet 21S presses the film body 24S against the molding surface of the upper mold 51 (specifically, the molding protrusion 51T), so that it is possible to prevent the film body 24S from curling or wrinkling.

[0056] Furthermore, by disposing the face material 25 between the film body 24S and the foamed sheet 21S, it is possible to prevent the binder from seeping out and adhering to one of the split dies (upper die 51 in this embodiment). Furthermore, by using a film body 24S in which the portions other than the cleavage initiation portion 40 are non-permeable, it is possible to suppress the binder from adhering to one of the split dies (upper die 51 in this embodiment). Furthermore, in this embodiment, since the film body 23S disposed on the lower side is non-permeable, it is also possible to prevent the binder from adhering to the other split dies (lower die 52 in this embodiment).

[0057] [Confirmatory experiment] The heat insulating effect of the reinforcement board was confirmed by the following confirmatory experiment. The details of the experimental example that was evaluated are shown in Figure 7 and are as follows.

[0058] 1. Configuration of the reinforcement board <Experimental Example 1> As a test sample of Experimental Example 1, a reinforcing board 10 was used that has the same laminated structure as the reinforcing board 10 of the above embodiment (see FIG. 2) and forms a gap of 7 mm between itself and an iron plate 91T (see FIG. 8) serving as a roof panel 91 by means of an upper recess 32. Specifically, the reinforcing board 10 of Experimental Example 1 is 200 mm long and 300 mm wide, with the thickness of the thickest part of the reinforcing board 10 (i.e., the total thickness of the upper protrusion 30 and the board main body 11) being 16 mm, and the thickness of the board main body 11 (the distance between the lower surface of the reinforcing board 10 and the bottom surface of the upper recess 32) being 9 mm. In addition, the upper protrusion 30 has a lattice shape when viewed in a plane, the distance between the centers of adjacent protrusions 31 is 100 mm, the width of the protrusion 31 (the width of the upper end surface of the protrusion 31) is 30 mm, and the depth of the upper recess 32 (the distance between the top surface 30M, which is the upper end surface of the upper protrusion 30, and the upper surface of the board main body 11) is 7 mm.

[0059] The foamed resin layer 21 is a semi-rigid polyurethane foam (apparent density: 22 kg / m) having an open cell structure and a thickness of about 17 mm. 3 (Note that this thickness is the thickness before press molding by the above-mentioned upper mold 51 and lower mold 52. The same applies to the following experimental examples.) Each reinforcing layer 22 has a basis weight of 150 g / m 2 The lower metal layer 23 is made of aluminum foil having a thickness of 100 μm, the upper metal layer 24 is made of aluminum foil having a thickness of 100 μm, and the face material 25 is made of aluminum foil having a thickness of 100 g / m 2 The upper metal layer 24 is formed of a nonwoven fabric. The upper metal layer 24 is provided only on the inner surface of the upper recess 32 (specifically, on a portion including the entire bottom surface of the upper recess 32).

[0060] <Experimental Example 2> In the second experimental example, only the lower metal layer 23 is provided out of the lower metal layer 23 and the upper metal layer 24. The other configurations are the same as those in the first experimental example.

[0061] <Experimental Example 3> In the third experimental example, only the upper metal layer 24 is provided out of the lower metal layer 23 and the upper metal layer 24. The other configurations are the same as those in the first experimental example.

[0062] <Experimental Example 4> Experimental Example 4 has the same laminated structure as the reinforcing board 10 of the above embodiment, but differs from Experimental Example 1 in that it does not have an upper recess 32. The thickness of the reinforcing board of Experimental Example 4 (thickness of the board main body portion 11) is 9 mm. The foamed resin layer 21 is composed of semi-rigid polyurethane foam with an open cell structure and a thickness of about 10 mm. Each reinforcing layer 22, each metal layer 23, 24, and each face material 25 are the same as those of Experimental Example 1. The reinforcing board of this experimental example is fully bonded to an iron plate 91T serving as a roof panel 91.

[0063] <Experimental Example 5> In the fifth experimental example, only the upper metal layer 24 is provided out of the lower metal layer 23 and the upper metal layer 24. The other configurations are the same as those in the fourth experimental example.

[0064] <Experimental Example 6> In the sixth experimental example, neither the lower metal layer 23 nor the upper metal layer 24 is provided (the sixth experimental example has the configuration of a conventional product).

[0065] <Experimental Example 7> In Experimental Example 7, the gap between the reinforcing board 10 and the iron plate 91T (see FIG. 8) serving as the roof panel 91 (i.e., the depth of the upper recess 32) is 5 mm, the thickness of the thickest part of the reinforcing board 10 is 14 mm, and the thickness of the board body 11 is 9 mm. The foamed resin layer 21 is made of semi-rigid polyurethane foam with an open cell structure and a thickness of about 15 mm. The other configurations are the same as those of Experimental Example 1.

[0066] <Experimental Example 8> In Experimental Example 8, the gap between the reinforcing board 10 and the iron plate 91T (see FIG. 8) serving as the roof panel 91 (i.e., the depth of the upper recess 32) is 2 mm, the thickness of the thickest part of the reinforcing board 10 is 11 mm, and the thickness of the board body 11 is 9 mm. The foamed resin layer 21 is made of semi-rigid polyurethane foam with an open cell structure and a thickness of about 12 mm. The other configurations are the same as those of Experimental Example 1.

[0067] 2. Evaluation Method <Thermal insulation performance> As shown in FIG. 8, the thermal insulation performance test was performed by irradiating infrared rays from an infrared irradiation device 62 to a cubic test box 60 installed in an atmosphere of 23° C. temperature and 50% humidity. The test box 60 is made of a hollow thermal insulation member, and only the upper surface is opened by an opening 61. The opening 61 was closed from the outside (from above) with an iron plate 91T (thickness 0.6 mm). A test sample 10A of a reinforcing board having a size (see Experimental Example 1) that fits into the opening 61 was attached to the lower surface of the iron plate 91T, and the test sample 10A was placed in the opening 61. The opening 61 was also closed from the inside (from below) of the test box 60 by a molded ceiling 92 (thickness 5 mm). The molded ceiling 92 was placed at a distance from the test sample 10A. For example, the upper wall of the test box 60 is made detachable, and the molded ceiling 92 is attached to the upper wall from below after removing the upper wall of the test box 60. Each side of the test box 60 is about 500 mm.

[0068] Then, the infrared irradiation device 62 irradiated infrared rays onto the iron plate 91T from the outside (from above) of the test box 60. The intensity of the infrared rays was set so that the temperature (iron plate temperature) of the position A on the upper surface of the iron plate 91T, which overlaps with the center of the reinforcement board test sample 10A in the thickness direction, was within the range of 100±0.5°C. Then, the temperature (under-ceiling temperature) of the position B, which was 90 mm directly below the position A (50 mm directly below the lower surface of the molded ceiling 92), was measured in the test box 60, and the difference obtained by subtracting the under-ceiling temperature from the iron plate temperature was evaluated as the heat insulating effect of the reinforcement board test sample 10A. In addition, the decrease (difference) in the under-ceiling temperature of the experimental examples 1 to 5, 7, and 8 compared to the under-ceiling temperature of the conventional product experimental example 6 was evaluated as the heat insulating effect of the conventional product.

[0069] 3. Evaluation results As shown in FIG. 7, it was confirmed that the reinforcing boards of Experimental Examples 1 to 3 and 7 to 8, which had a gap between them and the iron plate 91T, exhibited a better heat insulating effect than the reinforcing board of Experimental Example 6, which was a conventional product. In particular, in Experimental Example 1, which had both the lower metal layer 23 and the upper metal layer 24, the drop in temperature under the ceiling relative to the iron plate temperature was 51.4°C, which was 4.9°C lower than the conventional Experimental Example 6, and excellent heat insulating performance was exhibited. In addition, among Experimental Examples 2 and 3, which had only one of the lower metal layer 23 and the upper metal layer 24, Experimental Example 2, which had the lower metal layer 23, exhibited much better heat insulating performance. In addition, Experimental Example 7, in which the gap was changed to 5 mm compared to Experimental Example 1, exhibited excellent heat insulating performance, although it was slightly inferior to the heat insulating performance of Experimental Example 1. Similarly, Experimental Example 8, in which the gap was changed to 2 mm, also exhibited heat insulating performance. The results of Experimental Examples 1, and 7 to 8 show that excellent heat insulating performance is achieved by setting the gap to 5 mm or more.

[0070] Experimental examples 4 and 5, which were fully bonded to the iron plate 91T with no gap between them, had lower insulation performance than experimental examples 1 and 3, which had the same laminated structure. This is believed to be because the upper metal layer 24 was in close contact with the iron plate 91T, which facilitated the transfer of heat from the iron plate 91T. Experimental example 5, which only had the upper metal layer 24 as the metal layer, had worse insulation performance than the conventional product. From this, it is believed that when the iron plate 91T and the upper metal layer 24 are in direct contact with each other, the heat of the iron plate 91T is transferred to the reinforcing board through the upper metal layer 24, which has a high thermal conductivity, and the reinforcing board itself is heated, resulting in a deterioration in insulation performance. For this reason, it is preferable that the upper metal layer 24 is not disposed on the upper protrusion 30 (especially the top surface portion 30M, which is the upper surface of the upper protrusion 30 that is in contact with the iron plate 91T).

[0071] As described above, the reinforcing boards of Experimental Examples 1, 2, 7, and 8, which are arranged with a gap between them and the iron plate 91T and have at least the lower metal layer 23 as a metal layer, have excellent heat insulating performance. In particular, it was confirmed that the reinforcing boards of Experimental Examples 1, 2, and 7, which have a gap between them and the iron plate 91T of 5 mm or more, have very excellent heat insulating performance.

[0072] It should be noted that Experimental Examples 1, 2, 7, and 8 correspond to "Examples", and Experimental Examples 3 to 6 correspond to "Comparative Examples".

[0073] [Other embodiments] (1) In the above embodiment, the upper metal layer 24 may be formed, for example, by metal spraying after forming the laminate 20S (excluding the film body 24S in the above embodiment), that is, after forming the upper surface of the laminate 20S into a three-dimensional shape. In this case, it is easy to form the upper metal layer 24 only on the inner surface of the upper recess 32 on the upper surface of the reinforcing board 10. By forming the upper metal layer 24 only on the inner surface of the upper recess 32, the upper metal layer 24 is not provided on the top surface portion 30M of the reinforcing board 10 that contacts the roof panel 91, so that the heat insulating performance of the reinforcing board 10 can be further improved. In the manufacturing method of the reinforcing board 10 of this embodiment, if the part of the top surface portion 30M of the upper surface of the molded laminate 20S is protected with masking tape or the like and metal spraying is performed, it is possible to more reliably prevent metal particles from adhering to this part. In this embodiment, by forming the upper metal layer 24 by metal spraying, it is easy to provide the upper metal layer 24 with breathability. In addition, since the upper surface of the laminate 20S is formed into a three-dimensional shape before the upper metal layer 24 is formed, it becomes easy to form the upper metal layer 24 at a desired location (for example, the inner surface of the upper recess 32) on the upper surface of the reinforcing board 10. Note that, after forming the laminate 20S (excluding the film 24S), a metal foil may be placed on the inner surface of the upper recess 32 to form the upper metal layer 24. Also, after forming the laminate 20S excluding the film 23S, the lower metal layer 23 may be formed by metal spraying or metal foil.

[0074] (2) In the above embodiment, in manufacturing the reinforcing board 10, the separate film body 24S and the face material 25 are press-molded to obtain the integrated upper metal layer 24 and face material 25, but the upper metal layer 24 may be laminated and integrated with the face material 25 beforehand before press molding. In this case, for example, the upper metal layer 24 may be formed on at least one surface of the face material 25 by metal spraying, or the upper metal layer 24 may be formed by a metal foil attached to the face material 25. If the upper metal layer 24 is laminated on the face material 25 by metal spraying as in the former case, the binder can be reduced compared to the case where the upper metal layer 24 is laminated by adhering it to the face material 25 with a binder.

[0075] Specifically, when the upper metal layer 24 is formed before press molding of the laminate 20S (excluding the film 24S), for example, first, the face material 25 is sprayed with metal to form the upper metal layer 24. Then, the face material 25 and the upper metal layer 24 are laminated from above on the foamed sheet 21S, and the laminate is press molded by the upper mold 51 and the lower mold 52 to form the reinforcing board 10. In this case, the upper metal layer 24 may be disposed on the upper side or the lower side of the face material 25. In this case, by making the basis weight of the metal sprayed layer on the part of the face material 25 that overlaps the upper recess 32 in the thickness direction larger than the basis weight of the metal sprayed layer on the part constituting the top surface portion 30M, it is possible to prevent the upper metal layer 24 from being formed with an extremely thin part after press molding. Also, the upper die 51 for forming the upper surface of the reinforcing board 10 may be provided with a forming protrusion for forming the upper recess 32 of the reinforcing board 10, and metal may be sprayed only on the portion of the upper surface of the face material 25 that faces the forming protrusion of the upper die 51 during press molding. In this case, it is possible to easily form the upper metal layer 24 only on the inner surface of the upper recess 32. Furthermore, by forming the upper metal layer 24 by metal spraying, it is easy to make the upper metal layer 24 breathable. Here, in a configuration in which the upper metal layer 24 has breathability, if a binder is used for adhesion during molding of the laminate 20S, there is a risk that the binder will seep out through the upper metal layer 24 to the outside. Therefore, when the reinforcing board 10 is manufactured by press molding, there is a risk that the binder will adhere to the split die (upper die 51). In contrast, in this embodiment, the upper metal layer 24 is formed by metal spraying, so that the upper metal layer 24 can be formed by randomly depositing a large number of metal particles in multiple layers, and it is possible to suppress the seepage of the binder through the upper metal layer 24. This makes it possible to suppress adhesion of the binder to the split mold. In addition, the face material 25 can also suppress the seepage of the binder from the outer surface on the upper metal layer 24 side, and even if the upper metal layer 24 has a breathable configuration, it is possible to suppress the binder from leaking out to the outside. The lower metal layer 23 may be formed, for example, by metal spraying before press molding of the laminate 20S (excluding the film body 23S).

[0076] (3) In the above embodiment, when a plurality of upper protrusions 30 are provided, the upper protrusions 30 may be ridge-shaped, cylindrical or prismatic, or may be a truncated cone or pyramid shape tapering upward. When the upper protrusions 30 are ridge-shaped, for example, a plurality of bank-shaped protrusions (upper protrusions 30V) may extend in the front-rear direction or width direction of the vehicle 90 and be arranged parallel to each other (see FIG. 9(A)). In this case, when manufacturing the reinforcement board 10, the molding recesses 51U of the upper mold 51 may be formed into a plurality of grooves corresponding to the upper protrusions 30V, and a plurality of broken line portions 42 may be formed along the plurality of grooves as the cleavage starting points 40V in the film body 24S that becomes the upper metal layer 24 (see FIG. 9(B)). In this case, for example, instead of the broken line portions 42, slits may be provided that are slightly shorter than the broken line portions 42 and do not cross the film body 24S.

[0077] (4) In the above embodiment, the upper metal layer 24 is provided only in the upper recess 32, but as shown in Fig. 10, it may also be provided on the top surface 30M. In this case, the upper metal layer 24 may be provided on the entire upper surface of the reinforcing board 10 (see Fig. 10). Furthermore, when the upper metal layer 24 is provided only in the upper recess 32, it may be provided only on the bottom surface of the upper recess 32, or on the side surface of the upper recess 32 (the side surface of the upper protrusion 30), or on both the bottom surface and the side surface (see Fig. 11). Furthermore, the upper metal layer 24 does not have to be provided on the reinforcing board 10.

[0078] (5) In the above embodiment, at least one of the pair of reinforcing layers 22, 22 may not be provided, and at least one of the lower metal layer 23 and the upper metal layer 24 may be laminated directly on the foamed resin layer 21. Also, instead of the reinforcing layer 22 made of fiber, for example, a layer made of resin may be provided.

[0079] (6) In the above embodiment, a protrusion or a recess may be provided on the lower surface of the reinforcing board 10. In this case, for example, a recess may be provided on the lower surface of the reinforcing board 10 at a portion overlapping the upper protrusion 30 in the thickness direction. In this configuration, the foamed resin layer 21 may be raised upward to form the upper protrusion 30 and the recess. In this case, the thickness (basis weight) of the foamed resin layer 21 may be approximately uniform over the entire surface. In order to manufacture the reinforcing board 10 of this embodiment, an opposing protrusion for forming the recess of the reinforcing board 10 may be provided on the molding surface 52M of the lower mold 52 so as to face the molding recess 51U of the upper mold 51. In this case, the opposing protrusion can push the foamed sheet 21S up from below into the molding recess 51U during press molding, so that the film body 24S can be easily cleaved at the cleavage starting point.

[0080] (7) In the above embodiment, the adhesive 93 is disposed only on the top surface 30M, but it may be disposed on the entire upper surface of the reinforcing board 10 (i.e., the adhesive 93 may cover the entire top surface 30M and the upper recess 32). The presence of the adhesive 93 on the entire upper surface of the reinforcing board 10 makes it difficult for heat from the roof panel 91 to be transmitted to the reinforcing board 10, and the heat insulating performance of the reinforcing board 10 is further improved. Furthermore, the placement of the adhesive 93 on the entire upper surface of the reinforcing board 10 improves the rigidity of the reinforcing board 10. The adhesive 93 may be a transparent layer. This allows the upper metal layer 24 to reflect heat from the roof panel 91.

[0081] (8) In the above embodiment, the top surface portion 30M (upper protrusion 30) has a lattice shape in a plan view, but may have a honeycomb shape in a plan view. Even with this configuration, it is possible to improve the rigidity of the reinforcing board 10 in the front-rear direction and the vehicle width direction of the vehicle 90.

[0082] (9) In the above embodiment, the reinforcing board 10 is formed by hot pressing the laminate 20S, but the reinforcing board 10 may be formed by cold pressing the laminate 20S. In this case, an adhesive such as hot melt may be used as a binder.

[0083] (10) In the above embodiment, the entire upper end surface of the upper protrusion 30 (that is, the top surface portion 30M) is in close contact with the roof panel 91. However, the top surface portion 30M may be in close contact with the roof panel 91 only partially.

[0084] (11) In the above embodiment, the reinforcing board 10 is provided with the face material 25, but the face material 25 may not be provided. In this case, the upper metal layer 24 is directly laminated on the upper reinforcing layer 22. Also, a face material (e.g., similar to the face material 25) may be provided between the lower metal layer 23 and the lower reinforcing layer 22. [Explanation of symbols]

[0085] 10 Reinforcement board 21 Foamed resin layer 23 Lower metal layer 24 Upper metal layer 30M top section 32 Upper recess 90 vehicles 91 Roof Panel S Gap

Claims

1. A reinforcing board having a laminated structure including a foamed resin layer and bonded to the underside of a roof panel of a vehicle, An upper recess is formed on the upper surface to form a gap between the roof panel and the reinforcing board, a non-breathable layer laminated on the foamed resin layer from below; a first metal layer included in the non-breathable layer; A second metal layer is laminated on the foamed resin layer from above, A reinforcing board, wherein the second metal layer is a metal sprayed layer or a metal vapor deposition film.

2. A reinforcing board that is bonded to the underside of a roof panel of a vehicle and has a laminated structure including a foamed resin layer, An upper recess is formed on the upper surface to form a gap between the roof panel and the reinforcing board, a non-breathable layer laminated on the foamed resin layer from below; a first metal layer included in the non-breathable layer; A second metal layer is laminated on the foamed resin layer from above, A reinforcing board having an air-permeable surface material disposed between the foamed resin layer and the second metal layer.

3. A reinforcing board that is bonded to the underside of a roof panel of a vehicle and has a laminated structure including a foamed resin layer, An upper recess is formed on the upper surface to form a gap between the roof panel and the reinforcing board, a non-breathable layer laminated on the foamed resin layer from below; a first metal layer included in the non-breathable layer; an upper contact portion that is a portion of the upper surface of the reinforcing board other than the upper recess and that is in close contact with the roof panel; The upper adhesion portion of the reinforcing board has a lattice shape in a plan view.

4. A reinforcing board that is bonded to the underside of a roof panel of a vehicle and has a laminated structure including a foamed resin layer, An upper recess is formed on the upper surface to form a gap between the roof panel and the reinforcing board, a non-breathable layer laminated on the foamed resin layer from below; a first metal layer included in the non-breathable layer; a second metal layer laminated on the foamed resin layer from above; an upper contact portion that is a portion of the upper surface of the reinforcing board other than the upper recess and that is in close contact with the roof panel; A reinforcing board in which a proportion of the second metal layer provided on the inner surface of the upper recess is greater than a proportion of the second metal layer provided on the surface of the upper adhesive portion.

5. A reinforcing board that is bonded to the underside of a roof panel of a vehicle and has a laminated structure including a foamed resin layer, An upper recess is formed on the upper surface to form a gap between the roof panel and the reinforcing board, a non-breathable layer laminated on the foamed resin layer from below; a first metal layer included in the non-breathable layer; A second metal layer is laminated on the foamed resin layer from above, The second metal layer is provided only on the inner surface of the upper recess.

6. A reinforcing board that is bonded to the underside of a roof panel of a vehicle and has a laminated structure including a foamed resin layer, A recess is provided on the upper surface of the foamed resin layer, so that an upper recess is formed on the upper surface to form a gap between the roof panel and the reinforcing board, a non-breathable layer laminated on the foamed resin layer from below; A reinforcing board having a first metal layer included in the non-breathable layer.

7. A method for manufacturing a reinforcing board that is bonded to the underside of a roof panel of a vehicle and has a laminated structure including a foamed resin layer, An upper recess is formed on the upper surface to form a gap between the roof panel and the reinforcing board, a non-breathable layer laminated on the foamed resin layer from below; a first metal layer included in the non-breathable layer; A method for manufacturing a reinforcing board having a second metal layer laminated on the foamed resin layer from above, One of a pair of split dies for forming the reinforcing board by pressing is provided with a molding recess for molding an upper contact portion of the reinforcing board that comes into close contact with the roof panel at its rear surface, The second metal layer is made of a non-air-permeable metal foil, or a film body formed by laminating a non-air-permeable base layer with a metal sprayed layer or a metal vapor deposition layer as the second metal layer, is provided with a cleavage starting point portion which serves as a starting point for cleavage of the film body; In the method for manufacturing a reinforced board, when the film body is placed on the board material including the foamed resin layer between the pair of split dies during the pressing, the film body is placed closer to one of the split dies than the board material, and the molding recess and the crack starting point are overlapped.

8. A method for manufacturing a reinforcing board that is bonded to the underside of a vehicle roof panel and has a laminated structure including a foamed resin layer, An upper recess is formed on the upper surface to form a gap between the roof panel and the reinforcing board, a non-breathable layer laminated on the foamed resin layer from below; a first metal layer included in the non-breathable layer; A method for manufacturing a reinforcing board having a second metal layer laminated on the foamed resin layer from above, A method for manufacturing a reinforced board, comprising forming an upper surface of a board material including the foamed resin layer into a three-dimensional shape, and then spraying a metal onto the upper surface of the board material to form the second metal layer having breathability.

9. A method for manufacturing a reinforcing board that is bonded to the underside of a vehicle roof panel and has a laminated structure including a foamed resin layer, comprising: An upper recess is formed on the upper surface to form a gap between the roof panel and the reinforcing board, a non-breathable layer laminated on the foamed resin layer from below; a first metal layer included in the non-breathable layer; A method for manufacturing a reinforcing board having a second metal layer laminated on the foamed resin layer from above, The second metal layer is laminated to the face material by spraying metal onto the face material; A method for manufacturing a reinforcing board, comprising the steps of: stacking the foamed resin layer with the face material and the second metal layer from above; pressing the resulting layer with a pair of split dies to form the reinforcing board.

10. A method for manufacturing the reinforcing board according to claim 9, one of the pair of split dies for forming an upper surface of the reinforcing board is provided with a forming protrusion for forming the upper recess of the reinforcing board; A method for manufacturing a reinforcing board, in which, when forming the second metal layer, the metal is sprayed only onto a portion of the upper surface of the face material that faces the molding protrusion of one of the split dies during the press.

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