Board-type sunshade and automotive sunshade device equipped with said board-type sunshade

Abstract

[Problem] The present invention focuses on the characteristics of semi-rigid urethane foams and provides: a board-type sunshade obtained by impregnating, with a thermosetting resin, a semi-rigid urethane foam layer which contains at least a semi-rigid urethane foam, so as to further increase rigidity; and an automobile sunshade device using said board-type sunshade. [Solution] A sunshade 40 is obtained by layering a front member 40b, a core member 40a, and a back member 40c in this order, the core member 40a being formed by layering a resin-impregnated semi-rigid urethane foam layer 41 between glass fiber mats 42, 43.

Description

[Technical Field]

[0001] The present invention relates to a board-type sunshade and an automobile sunshade device equipped with the board-type sunshade. [Background technology]

[0002] Generally, board-type sunshades are desirable to be lightweight for ease of handling. For example, when a board-type sunshade is installed in a car as a sunshade device, in recent years, lightweight board-type sunshades have been required from the perspective of improving the fuel efficiency of the car. Furthermore, in order to maintain its board shape well, the sunshade is required to be a strong sunshade with rigidity that is resistant to deformation.

[0003] In response to these requirements, conventionally, the sunshade for an automobile sunroof described in Patent Document 1 below has been disclosed as an example of this type of board-type sunshade.

[0004] In addition to its lightweight nature, the sunshade maintains sufficient rigidity to retain its board-like shape. To achieve this, the core of the sunshade is formed using a semi-rigid polyurethane foam layer and a double-resin impregnated glass fiber mat. Under these conditions, the core of the sunshade is formed by laminating the semi-rigid polyurethane foam layer between the double-resin impregnated glass fiber mat.

[0005] In the core component, both resin-impregnated glass fiber mats are formed by impregnating glass fiber mats with liquid thermosetting resin and allowing them to harden. Although this contributes to an increase in the weight of the sunshade, it aims to meet the demand for increased rigidity in the sunshade.

[0006] On the one hand, since the semi-rigid urethane foam layer is lightweight, it can suppress a further increase in weight as a core member. Further, since the semi-rigid urethane foam layer has flexibility suitable as a material for the core member of the sunshade, it forms the core member together with the both-resin-impregnated glass fiber mat.

[0007] Thus, an outer skin layer formed from an outer skin material is laminated from its front surface side to one of the both-resin-impregnated glass fiber mats of the core member, while a back skin layer formed from a back skin material is laminated from its back surface side to the other both-resin-impregnated glass fiber mat.

[0008] In this way, the outer skin layer, one both-resin-impregnated glass fiber mat, the semi-rigid urethane foam layer, the other both-resin-impregnated glass fiber mat, and the back skin layer are laminated to form a multi-layer laminate. The multi-layer laminate thus formed is formed into a sunshade by being heated and pressed by a press mold and compression-molded.

Prior Art Documents

Patent Documents

[0009]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0010] By the way, in the sunshade configured as described above, the both-resin-impregnated glass fiber mats are formed by impregnating a glass fiber mat with a liquid thermosetting resin and curing it as described above.

[0011] In the above-described impregnation, in order to further enhance the rigidity of the resin-impregnated glass fiber mat, it is desirable to increase the basis weight of the liquid thermosetting resin impregnated into the glass fiber mat.

[0012] However, while the rigidity of the sunshade can be primarily ensured by the two resin-impregnated glass fiber mats, these two glass fiber mats contribute to the weight increase, as mentioned above. Therefore, from the standpoint of weight reduction, it is desirable to keep the weight of each glass fiber mat as low as possible.

[0013] For these reasons, the amount of liquid thermosetting resin impregnating the fiberglass mat is inevitably limited. This is the reason why it is not possible to meet the recent demand for further improvements in the rigidity and, consequently, the strength of the board-type sunshade.

[0014] Therefore, in order to address the above issues, the present invention aims to provide a board-type sunshade and an automobile sunshade device equipped with the board-type sunshade, which have increased rigidity by focusing on the characteristics of semi-rigid foamed urethane and impregnating and curing a semi-rigid foamed urethane layer made of said semi-rigid foamed urethane with a liquid thermosetting resin. [Means for solving the problem]

[0015] In addressing the above problems, the board-type sunshade according to the present invention is It consists of an outer skin member, an inner skin member, and a core member laminated between these outer and inner skin members.

[0016] In the board-type sunshade, The core member is, A first resin-impregnated glass fiber mat is formed by impregnating a glass fiber mat with a liquid thermosetting resin throughout and curing it, A second resin-impregnated glass fiber mat is formed by impregnating a glass fiber mat with a liquid thermosetting resin throughout and curing it, It comprises a resin-impregnated semi-rigid foamed urethane layer formed by impregnating a semi-rigid foamed urethane layer with a liquid thermosetting resin throughout and curing it, The resin-impregnated semi-rigid polyurethane foam layer is laminated between the first and second resin-impregnated glass fiber mats. The liquid thermosetting resin impregnating each of the first and second resin-impregnated glass fiber mats is 20 g / m², which is the first predetermined basis weight range. 2 ~50g / m 2 It has a weight within the range, The liquid thermosetting resin impregnated into the semi-rigid foamed urethane layer is 100 g / m², which is the second predetermined basis weight range. 2 ~500g / m 2 It has a weight within the range of [specify range].

[0017] With this configuration, the core member is as described above. A first resin-impregnated glass fiber mat formed by impregnating a glass fiber mat with a liquid thermosetting resin throughout and curing it; a second resin-impregnated glass fiber mat formed by impregnating a glass fiber mat with a liquid thermosetting resin throughout and curing it; and a resin-impregnated semi-rigid foamed urethane layer formed by impregnating a semi-rigid foamed urethane layer with a liquid thermosetting resin throughout and curing it. It is equipped with this. Here, The resin-impregnated semi-rigid polyurethane foam layer is laminated between the first and second resin-impregnated glass fiber mats. . According to this, the core member is formed of a resin-impregnated semi-rigid foamed urethane layer and first and second resin-impregnated glass fiber mats. In other words, the core member is formed to have rigidity that is the sum of the rigidity of the resin-impregnated semi-rigid foamed urethane layer and the rigidity of the first and second resin-impregnated glass fiber mats. Therefore, the rigidity of the board-type sunshade described above can be further enhanced in the resin-impregnated semi-rigid foamed urethane layer and the first and second resin-impregnated glass fiber mats compared to the case where the first and second resin-impregnated glass fiber mats are glass fiber mats that are not impregnated with resin. Furthermore, the liquid thermosetting resin impregnated into each of the first and second resin-impregnated glass fiber mats is 20 g / m², which is the first predetermined basis weight range. 2 ~50g / m 2 The basis weight is within the range of the resin-impregnated semi-rigid foamed urethane layer, and the liquid thermosetting resin impregnated into the semi-rigid foamed urethane layer is 100 g / m², which is the second predetermined basis weight range. 2 ~500g / m 2 It has a weight within the range of [specify range]. This allows the above-mentioned effects to be achieved more concretely.

[0032] Furthermore, the present invention configured in this manner In the board-type sunshade described above, The skin member consists of a skin layer and an adhesive layer on the skin layer side. The backing material consists of a backing layer and an adhesive layer on the backing layer side. core In the component , the first and second trees Oil-impregnated fiberglass mat one of One resin-impregnated glass fiber mat is bonded to the epidermal layer by the epidermal layer-side adhesive layer, so as to face the epidermal layer via the epidermal layer-side adhesive layer, and the other , other than the first and second resin-impregnated glass fiber mats The resin-impregnated glass fiber mat may be bonded to the backing layer by the backing layer-side adhesive layer so as to face the backing layer via the backing layer-side adhesive layer.

[0033] Thus, the core member , the first and second trees Even in a structure in which a resin-impregnated semi-rigid foamed urethane layer is laminated between oil-impregnated glass fiber mats, the effects and advantages of the present invention can be achieved more concretely by specifying the configuration of the outer and inner layers, and by specifying the laminated configuration between the outer and inner layers of the core, as described above.

[0039] Also The book is constructed as described above. In the invention, the liquid thermosetting resin may be a liquid isocyanate.

[0043] Also, this Automotive sunshade device related to the present , It is applied to the sunroof of a car body. In the said automobile sunshade device, The sunshade comprises a board-type sunshade consisting of an outer skin member, an inner skin member, and a core member laminated between the outer skin member and the inner skin member, and a plurality of sliding members attached to at least the rear portions of both left and right side edges of the board-type sunshade. The sunroof is formed by an outer panel and an inner panel located inside the outer panel. The outer panel has an outer panel opening formed to form a sunroof window, and the inner panel has an inner panel opening formed to face the outer panel opening. The board-type sunshade is supported on the outer panel so as to be slidable in the front-rear direction via left and right side guide rails, which are arranged in the front-rear direction along the left and right sides of the openings of the outer panel and the openings of the inner panel, along with a plurality of sliding members between the outer panel and the inner panel. In a board-type sunshade, core The component 、 The first resin impregnation is formed by impregnating a glass fiber mat with a liquid thermosetting resin throughout and allowing it to harden. glass fiber mat To and, A second resin-impregnated glass fiber mat is formed by impregnating a glass fiber mat with a liquid thermosetting resin throughout and curing it, A resin-impregnated semi-rigid foamed urethane layer is formed by impregnating a semi-rigid foamed urethane layer with a liquid thermosetting resin throughout and allowing it to harden. and includes 、 The tree a semi-rigid foam urethane layer impregnated with resin The first and second trees which is laminated between the resin-impregnated glass fiber mats 、 In each of the first and second resin-impregnated glass fiber mats, the liquid thermosetting resin impregnated into the glass fiber mat is 20 g / m², which is the first predetermined basis weight range. 2 ~50g / m 2 It has a weight within the range, In the resin-impregnated semi-rigid foamed urethane layer, the liquid thermosetting resin impregnated into the semi-rigid foamed urethane layer is 100 g / m², which is a second predetermined basis weight range. 2 ~500g / m 2 It has a weight within the range of [specify range].

[0044] According to such a configuration The automobile sunshade device according to the present invention comprises a board-type sunshade consisting of a surface member, a backing member, and a core member laminated between the surface member and the backing member, and a plurality of sliding members attached to at least the rear portions of both left and right side edges of the board-type sunshade. Here, the sunroof is formed by an outer panel and an inner panel located inside the outer panel. The outer panel has an outer panel opening formed to form a sunroof window, and the inner panel has an inner panel opening formed to face the outer panel opening. The board-type sunshade is supported on the outer panel so as to be slidable in the front-to-back direction via left and right side guide rails, which are arranged in the front-to-back direction along the left and right sides of the openings in the outer panel and the openings in the inner panel, along with a plurality of sliding members, between the outer panel and the inner panel. the said In a board-type sunshade, the core member is: A first resin-impregnated glass fiber mat is formed by impregnating a glass fiber mat with a liquid thermosetting resin throughout and curing it, A second resin-impregnated glass fiber mat is formed by impregnating a glass fiber mat with a liquid thermosetting resin throughout and curing it, A resin-impregnated semi-rigid foamed urethane layer is formed by impregnating a semi-rigid foamed urethane layer with a liquid thermosetting resin throughout and allowing it to harden. and They are equipped, The resin-impregnated semi-rigid polyurethane foam layer is laminated between the first and second resin-impregnated glass fiber mats. According to this, the core member is formed of a resin-impregnated semi-rigid foamed urethane layer and first and second resin-impregnated glass fiber mats. In other words, the core member is formed to have rigidity that is the sum of the rigidity of the resin-impregnated semi-rigid foamed urethane layer and the rigidity of the first and second resin-impregnated glass fiber mats. Therefore, the rigidity of the board-type sunshade described above can be further enhanced compared to the case where the first and second resin-impregnated glass fiber mats are glass fiber mats that are not impregnated with resin, in the resin-impregnated semi-rigid foamed urethane layer and the first and second resin-impregnated glass fiber mats. This means that the automobile sunshade according to the present invention can be further enhanced in terms of its rigidity, based on the further enhancement of the rigidity of the board-type sunshade described above. Furthermore, in each of the first and second resin-impregnated glass fiber mats, the liquid thermosetting resin impregnated into the glass fiber mat is 20 g / m², which is the first predetermined basis weight range. 2 ~50g / m 2 The basis weight is within the range of the resin-impregnated semi-rigid foamed urethane layer, and the liquid thermosetting resin impregnated into the semi-rigid foamed urethane layer is 100 g / m², which is the second predetermined basis weight range. 2 ~500g / m 2 It has a basis weight within the range of [specify range]. This allows the effects and benefits of the automotive sunshade device according to the present invention to be achieved more concretely. Based on the above, it is possible to achieve the effects described above.Equipped with a cord-type sunshade Automotive We can provide a shade device.

[0045] Furthermore, the automotive sunshade device according to the present invention is applied to the sunroof of an automobile. The said In a sunshade device for a motor vehicle, It comprises a board-type sunshade and multiple sliding members. The sunroof is formed by an outer panel and an inner panel located inside the outer panel. The outer panel has an outer panel opening formed to form a sunroof window, and the inner panel has an inner panel opening formed to face the outer panel opening. The board-type sunshade is formed from a laminate consisting of an outer skin member, an inner skin member, and a core member laminated between the outer skin member and the inner skin member, and has a flat central portion, front and rear side ends extending from the flat central portion to both the front and rear sides and formed by compression at a higher compression ratio than the flat central portion, and left and right side edges extending from the flat central portion to both the left and right sides. Here, of the front and rear ends, the front end is further formed to curve toward the backing material with a gently convex curved shape toward the front. Furthermore, each of the left and right side edges comprises a front portion and the remaining portion excluding the front portion, which is formed by compression at a higher compression ratio than that of the flat central portion. The front portions of each of the left and right edges are formed by compression at a lower compression ratio than the remaining portions. Furthermore, in the board-type sunshade, the core member is A first resin-impregnated glass fiber mat is formed by impregnating a glass fiber mat with a liquid thermosetting resin throughout and curing it, A second resin-impregnated glass fiber mat is formed by impregnating a glass fiber mat with a liquid thermosetting resin throughout and curing it, It comprises a resin-impregnated semi-rigid foamed urethane layer formed by impregnating a semi-rigid foamed urethane layer with a liquid thermosetting resin throughout and curing it, The resin-impregnated semi-rigid polyurethane foam layer is laminated between the first and second resin-impregnated glass fiber mats. Also, In each of the first and second resin-impregnated glass fiber mats, the liquid thermosetting resin impregnated into the glass fiber mat is 20 g / m², which is the first predetermined basis weight range. 2 ~50g / m 2 It has a weight within the range, In the resin-impregnated semi-rigid foamed urethane layer, the liquid thermosetting resin impregnated into the semi-rigid foamed urethane layer is 100 g / m², which is a second predetermined basis weight range. 2 ~500g / m 2 It has a weight within the range of [specify range]. Furthermore, multiple sliding members are attached to at least the rear portions of both the left and right edges of the board-type sunshade. Under this configuration, the board-type sunshade is supported on the outer panel so as to be slidable in the front-to-back direction via left and right side guide rails, which are arranged in the front-to-back direction along the left and right sides of the openings of the outer panel and the openings of the inner panel, along with a plurality of sliding members, between the outer panel and the inner panel.

[0046] With the above configuration, the automobile sunshade device according to the present invention further The board-type sunshade is formed from a laminate consisting of an outer skin member, an inner skin member, and a core member laminated between the outer skin member and the inner skin member, and has a flat central portion, front ends extending from the flat central portion to both the front and rear sides and formed by compression at a higher compression ratio than the flat central portion, rear ends extending from the flat central portion to both the front and rear sides and formed by compression at a higher compression ratio than the flat central portion, and left and right side edges extending from the flat central portion to both the left and right sides. Here, the front end is further formed to curve toward the backing material with a gently convex curved shape toward the front. According to this, as mentioned above, pressure In a board-type sunshade, which is a molded laminate formed by shrink molding, the front end of the sunshade is formed to curve toward the backing material with a gently convex curve towards the front. Therefore, the core material is not exposed toward the surface material, and the aesthetic appearance of the board-type sunshade can be well maintained.

[0047] Furthermore, as mentioned above, both left and right edges Each part comprises a front portion and the remaining portion excluding the front portion, which is formed by compression at a higher compression ratio than that of the flat central portion. The front portions of each of the left and right edges are formed by compression at a lower compression ratio than the remaining portions. Here, as mentioned above, left Of the right side edges , remainder part pressure Reduction rate The compression ratio of the flat central part is greater than Because it is expensive, the remaining parts of the core material as described above Each The corresponding parts also become more rigid. Consequently, the outer perimeter of the board-type sunshade becomes harder. As a result, when opening and closing the sunshade device, the board-type sunshade can maintain its original board shape well without deforming even when subjected to external forces.

[0048] Also As mentioned above, left The front portions of both right edges are ,left The right side edges are formed with a lower compression ratio than the remaining portions. Therefore, if each front portion is used as a support portion instead of a front sliding member, and sliding members are assembled to the rear portions of the left and right side edges, when the sunshade device is attached to the sunroof of a car via left and right guide rails, the board-type sunshade can slide smoothly along each support portion and each support portion along the inside of the left and right guide rails without employing front sliding members. [Brief explanation of the drawing]

[0049] [Figure 1] This is a schematic plan view of a partially broken automobile to which the first embodiment of the sunshade device according to the present invention is applied. [Figure 2] Figure 1 is a schematic plan view showing the automobile with the sunshade of the sunshade device in the open position. [Figure 3] Figure 1 is a schematic surface view showing the sunshade device as seen from its surface (side of the car's interior). [Figure 4] Figure 1 is a schematic rear view showing the sunshade device as viewed from its underside (the side of the car's roof). [Figure 5] This is an enlarged longitudinal cross-sectional view of the sunshade device along line 5-5 in Figure 3. [Figure 6] Figure 1 is a schematic surface view of the sunshade as seen from its front side. [Figure 7] Figure 1 is a schematic rear view of the sunshade as seen from its reverse side. [Figure 8] This is an enlarged longitudinal cross-sectional view of the sunshade along line 8-8 in Figure 6. [Figure 9] Figure 8 is an enlarged partial cross-sectional view showing a portion of the sunshade indicated by circle A. [Figure 10] This is an enlarged exploded perspective view of the sunshade before resin impregnation in the core member of the first embodiment described above. [Figure 11] This is a diagram showing the maximum load and bending elasticity gradient for the test sample and comparative sample in the first embodiment described above. [Figure 12] This is a schematic diagram showing the bending strength testing apparatus in the first embodiment described above. [Figure 13] This is an enlarged longitudinal cross-sectional view of a sunshade in a second embodiment of the sunshade device according to the present invention. [Figure 14] Figure 13 is an enlarged cross-sectional view showing a portion of the sunshade, indicated by circle B. [Figure 15] This is a schematic rear view of the sunshade in the third embodiment of the sunshade device according to the present invention, as seen from the back side. [Figure 16] This is an enlarged longitudinal cross-sectional view showing the sunshade in the third embodiment described above. [Figure 17] Figure 15 is an enlarged side view showing the sunshade device as seen from the direction of arrow C. [Figure 18] This is a cross-sectional view along line 18-18 in Figure 15. [Figure 19] This is a cross-sectional view along line 19-19 in Figure 15. [Figure 20] This is a cross-sectional view along line 20-20 in Figure 15. [Modes for carrying out the invention]

[0050] Hereinafter, embodiments of the present invention will be described with reference to the drawings. (First Embodiment) Figure 1 shows a first embodiment of a sunshade device to be applied to an automobile. The automobile has a body 10, and a window WD is provided in the roof 20 of the body 10. As shown in Figure 1 or Figure 2, the window WD is formed by a transparent panel fitted into an opening 21a (hereinafter also referred to as the outer panel opening 21a) formed in the outer panel 21 of the roof 20. In this first embodiment, the sunshade device is hereafter referred to by the reference numeral SD.

[0051] In this first embodiment, the roof 20 having the window WD serves as the sunroof of the automobile (hereinafter also referred to as the sunroof 20). The roof 20 is composed of an outer panel 21 and an inner panel (not shown) inside it, and an opening (hereinafter also referred to as the inner panel opening) is formed in the inner panel at the part corresponding to the outer panel opening 21a. In Figures 1 and 2, the right and left sides correspond to the front and rear sides of the vehicle body 20, respectively.

[0052] The sunshade device SD is applied to the sunroof 20 of the vehicle, and the sunshade device SD is supported on the outer panel 21 so as to be slidable in the front-rear direction via left and right side guide rails 30 so as to be able to face the window WD (see Figure 1 or Figure 2). The left and right side guide rails 30 are each formed in a U-shape in cross-section, and the left and right side guide rails 30 are attached from the inner panel side along the left and right portions of the outer panel opening 21a of the outer panel 21 so as to face each other in the left-right direction at their respective longitudinal openings (see Figure 1).

[0053] However, when the sunshade device SD blocks light from the window WD from entering the vehicle interior, it is positioned at the location shown in Figure 1 (hereinafter also referred to as the blocking position). Furthermore, when the sunshade device SD allows light from the window WD to enter the vehicle interior, it slides along the left and right guide rails 30 to the position shown in Figure 2 (hereinafter also referred to as the incident position). When the sunshade device SD is in the incident position, it is positioned between the outer panel 21 and the inner panel of the roof 20.

[0054] The sunshade device SD comprises a board-type sunshade 40, a knob 50, and four sliding members 60, as shown in any of Figures 3 to 5. The board-type sunshade 40 comprises a core member 40a, a surface member 40b, and a backing member 40c, as shown in any of Figures 3 to 9. The backing member 40c, core member 40a, and surface member 40b are laminated in this order and formed as the sunshade 40 by press molding.

[0055] As shown in Figure 9, the core member 40a comprises a resin-impregnated semi-rigid foamed urethane layer 41 and two glass fiber mats 42 and 43, with the resin-impregnated semi-rigid foamed urethane layer 41 laminated between the two glass fiber mats 42 and 43. In this first embodiment, of the two glass fiber mats 42 and 43, glass fiber mat 42 is also referred to as the surface layer side glass fiber mat 42, while glass fiber mat 43 is also referred to as the back layer side glass fiber mat 43.

[0056] The resin-impregnated semi-rigid foamed urethane layer 41 is formed by impregnating the semi-rigid foamed urethane layer 41a (see Figure 10) with a liquid thermosetting resin and curing it. In this first embodiment, Figure 10 shows an exploded perspective view of a laminated structure (corresponding to the laminated structure of a board-type sunshade 40) in which the surface layer 45 and barrier film 44, the surface layer side glass fiber mat 42, the semi-rigid foamed urethane layer 41a before resin impregnation, the back layer side glass fiber mat 43, adhesive film 46 and back layer 47 are laminated.

[0057] In this laminated structure, the barrier film 44 and the surface layer 45 constitute the surface member 40b (described later), the surface layer-side glass fiber mat 42, the semi-rigid foamed urethane layer 41a, and the back layer-side glass fiber mat 43 constitute the core member Nc (corresponding to the core member 40a) before resin impregnation, and the adhesive film 46 and the back layer 47 constitute the back member 40c (described later).

[0058] The reason for adopting semi-rigid polyurethane foam in the resin-impregnated semi-rigid polyurethane foam layer 41, as described above, is as follows:

[0059] Polyurethane foam is typically formed by foaming open-cell and closed-cell polyurethane. The more open-cell polyurethane foam has compared to the number of closed-cell polyurethane foams, the softer and more flexible it becomes, approaching the characteristics of soft polyurethane foam. Conversely, the more closed-cell polyurethane foam has compared to the number of open-cell polyurethane foams, the harder it becomes, improving its rigidity, approaching the characteristics of rigid polyurethane foam.

[0060] Therefore, as the semi-rigid foamed urethane 41a for board-type sunshades, it is desirable to use foamed urethane (semi-rigid foamed urethane) in which open cells and closed cells are formed in the urethane so as to have a hardness corresponding to the rigidity that can maintain the shape of the board well in the board-type sunshade.

[0061] The semi-rigid polyurethane foam layer 41a, formed using such semi-rigid polyurethane foam, has excellent breathability due to its numerous open cells, and also effectively serves as the main component of the core member 40a of the board-type sunshade 40. Furthermore, as mentioned above, because the semi-rigid polyurethane foam layer 41a has excellent breathability, liquid thermosetting resins can easily impregnate the semi-rigid polyurethane foam layer 41a.

[0062] The semi-rigid polyurethane foam layer 41a is formed in layers using semi-rigid polyurethane foam having a basis weight within a predetermined basis weight range. The predetermined basis weight range is 100 g / m². 2 )~300(g / m 2 This refers to the range of ). Within the said predetermined weight range, the lower limit is set to 100 (g / m²). 2 The reason for setting the upper limit to 300 (g / m²) is to prevent the semi-rigid polyurethane foam layer 41a from becoming too soft and compromising its semi-rigid properties suitable for board-type sunshades. 2 The reason for this is to prevent the semi-rigid polyurethane foam layer 41a from becoming too hard and compromising its semi-rigid properties, which are suitable for board-type sunshades.

[0063] Furthermore, the resin impregnating the semi-rigid foamed urethane layer 41a is a thermosetting resin, which is applied in liquid form to the semi-rigid foamed urethane layer 41a from both sides over its entire surface, and is impregnated into the semi-rigid foamed urethane layer 41a and cured. , resin impregnated semi- It is formed as a rigid polyurethane foam layer 41.

[0064] As a result, the resin-impregnated semi-rigid foamed urethane layer 41 is formed to have high rigidity throughout, allowing it to maintain its original plate shape (board shape) well without being affected by external forces (see Figure 9).

[0065] In this first embodiment, the thermosetting resin mentioned above is, for example, isocyanate. The amount of isocyanate impregnating the semi-rigid foamed urethane layer 41a is set to a value within a predetermined basis weight range. Here, the predetermined basis weight range is set to a range in which the resin-impregnated semi-rigid foamed urethane layer 41 can exhibit high rigidity throughout its entirety, maintaining its original plate shape (board shape) without being affected by external forces.

[0066] In this first embodiment, the predetermined basis weight range for the isocyanate impregnated into the semi-rigid foamed urethane layer 41a described above is 100 g / m². 2 )~500(g / m 2 ) is set. Within the specified range of basis weight, the lower limit is 100 (g / m²). 2 ) was set to 100 (g / m 2 Below 500 (g / m²), the resin-impregnated semi-rigid foamed urethane layer 41 may not be able to maintain its original plate shape properly due to insufficient rigidity. 2 ) was set to 500 (g / m 2 If the amount exceeds ), the liquid isocyanate may seep out from the surface of the impregnated semi-rigid foamed urethane layer 41a (resin-impregnated semi-rigid foamed urethane layer 41), potentially damaging the appearance of the resin-impregnated semi-rigid foamed urethane layer 41.

[0067] Furthermore, both glass fiber mats 42 and 43 are formed in a mat shape by intertwining a large number of glass fibers. As a result, both glass fiber mats 42 and 43 have a structure that can exhibit good rigidity based on the intertwined structure of a large number of rigid glass fibers.

[0068] However, of the two glass fiber mats 42 and 43, the glass fiber mat 42 on the surface layer side is laminated along the surface (side surface of the surface layer) of the resin-impregnated semi-rigid foamed urethane layer 41. On the other hand, the glass fiber mat 43 on the back layer side is laminated along the back surface (side surface of the back layer) of the resin-impregnated semi-rigid foamed urethane layer 41.

[0069] In this way, the glass fiber mats 42 and 43 on the surface layer side and the back layer side, with their respective rigidities, sandwich the resin-impregnated semi-rigid foamed urethane layer 41, thereby playing an auxiliary role in maintaining the resin-impregnated semi-rigid foamed urethane layer 41 in its original plate shape (board shape).

[0070] Here, the role of the core member 40a in the board-type sunshade will be explained. As the name suggests, this board-type sunshade is a sunshade in the shape of a board, or plate. Since this board-type sunshade is configured as a device and mounted on the sunroof 20 (roof 20) of an automobile, it is required that the opening and closing of the window of the sunroof 20 be easily moved in the front-rear direction along the outer panel 21 of the sunroof 20, and that it have a lightweight plate shape with high rigidity that is resistant to deformation.

[0071] To meet this requirement, it is essential that the core member 40a, which is the main component of the sunshade 40 in the board-type sunshade device SD, has high rigidity. For this reason, in this first embodiment, the core member 40a is formed by a laminated structure of a resin-impregnated semi-rigid foamed urethane layer 41 and two glass fiber mats 42 and 43, as described above.

[0072] Here, the resin-impregnated semi-rigid foamed urethane layer 41 is obtained by impregnating the entire semi-rigid foamed urethane layer 41a with liquid isocyanate, a type of liquid thermosetting resin, as described above, and then curing it.

[0073] Thus, the reason for selecting the semi-rigid foamed urethane layer 41a, rather than the two glass fiber mats 42 and 43, as the target for impregnation with liquid isocyanate is as follows:

[0074] In recent years, there has been a demand for increased rigidity in board-type sunshades. However, although the two glass fiber mats 42 and 43 have higher rigidity than the semi-rigid foamed urethane layer 41a due to their structure, the two glass fiber mats 42 and 43 are made of glass fibers. For this reason, the two glass fiber mats 42 and 43 are considerably heavier than the semi-rigid foamed urethane layer 41a, which is made of foamed urethane.

[0075] Therefore, from the standpoint of reducing the weight of the sunshade 40, there are naturally limitations on increasing the basis weight of each of the glass fiber mats 42 and 43. Consequently, there are also limitations on increasing the basis weight of the liquid isocyanate impregnated into each of the glass fiber mats 42 and 43.

[0076] Furthermore, since each glass fiber mat 42 and 43 is formed from a large number of glass fibers, it does not have the same breathability as the semi-rigid foamed urethane layer 41a. For this reason, the liquid isocyanate does not easily penetrate both glass fiber mats 42 and 43. Consequently, the total basis weight of the liquid isocyanate when impregnating both glass fiber mats 42 and 43 is considerably less than the basis weight of the liquid isocyanate impregnating the semi-rigid foamed urethane layer 41a described above.

[0077] In this case, even if liquid isocyanate is impregnated and cured into both glass fiber mats 42 and 43, the rigidity of each of the glass fiber mats 42 and 43 cannot be increased to a degree that can meet the recent demand for increased rigidity in the aforementioned board-type sunshades.

[0078] In contrast, the semi-rigid polyurethane foam layer 41a has good breathability due to its foam structure, so liquid isocyanate easily penetrates into the semi-rigid polyurethane foam layer 41a. This means that the basis weight of liquid isocyanate impregnating the semi-rigid polyurethane foam layer 41a can be increased much more easily than when impregnating both glass fiber mats 42 and 43.

[0079] In other words, the basis weight of the semi-rigid polyurethane foam layer 41a is the respective weight of the glass fiber mats 42 and 43 Basis Since the amount can be increased considerably compared to the previous amount, the basis weight of the liquid isocyanate that can be impregnated into the semi-rigid foamed urethane layer 41a can be increased even further than the basis weight of the liquid isocyanate impregnated into each of the glass fiber mats 42 and 43.

[0080] For the reasons described above, the predetermined basis weight range for the isocyanate impregnated into the semi-rigid polyurethane foam layer 41a is set to 100 (g / m²). 2 )~500(g / m 2 ) was set. Furthermore, in this first embodiment, the basis weight of the isocyanate impregnated into the semi-rigid foamed urethane layer 41a is more preferably 200 g / m². 2 ±20g / m 2 A value within (for example, 200g / m³) 2 )

[0081] With the above in mind, in this first embodiment, the liquid isocyanate is uniformly impregnated into the semi-rigid foamed urethane layer 41a. Furthermore, as described above, the basis weight of the semi-rigid foamed urethane layer 41a can be considerably increased compared to the basis weights of the glass fiber mats 42 and 43 individually. Therefore, the amount of liquid isocyanate that can be impregnated into the semi-rigid foamed urethane layer 41a can be increased even further than the sum of the basis weights of liquid isocyanate that can be impregnated into each of the glass fiber mats 42 and 43.

[0082] Since the isocyanate described above is a thermosetting resin, if the liquid isocyanate impregnated throughout the semi-rigid foamed urethane layer 41a as described above is cured, a core member with much higher rigidity can be formed as the core member 40a of the sunshade 40 compared to the case where the liquid isocyanate is impregnated and cured into each of the glass fiber mats 42 and 43.

[0083] Therefore, as described above, the rigidity of the resin-impregnated semi-rigid foamed urethane layer 41, formed by impregnating and curing liquid isocyanate into the semi-rigid foamed urethane layer 41a, can be increased by a much greater margin than the sum of the individual rigidities of the two glass fiber mats formed by impregnating and curing liquid isocyanate. This means that the requirement for increased rigidity of the sunshade, as stated at the beginning of this specification, can be fully met.

[0084] As illustrated in Figure 9, the surface member 40b comprises a barrier film 44 and a surface layer 45. The barrier film 44 has adhesive properties and gas sealing properties, and the barrier film 44 has adhesive properties on both its front and back surfaces.

[0085] Accordingly, the barrier film 44, based on its adhesive properties, plays a role in bonding the surface layer-side glass fiber mat 42 to the surface layer 45. Furthermore, based on its gas sealing properties, the barrier film 44 plays a role in sealing the leakage of gas released from the resin-impregnated semi-rigid foamed urethane layer 41 to the outside when the sunshade 40 is formed by press molding.

[0086] The surface layer 45 is formed in layers using a predetermined surface material. The surface layer 45 is bonded and laminated along the surface layer-side glass fiber mat 42 by a barrier film 44 so as to face the resin-impregnated semi-rigid foamed urethane layer 41 via the surface layer-side glass fiber mat 42. The surface layer 44 faces the interior of the vehicle with its surface (the side facing the interior of the vehicle). Examples of the predetermined surface material mentioned above include polyurethane foam laminate knitted fabric, fabric, and needle-punched nonwoven fabric.

[0087] The backing material 40c comprises an adhesive film 46 and a backing layer 47, as illustrated in Figure 9. The adhesive film 46 plays the role of adhering the backing layer-side glass fiber mat 43 to the backing layer 47 based on its adhesive properties. The adhesive film 46 exhibits adhesive function on both its front and back surfaces.

[0088] The backing layer 47 is formed in layers using a predetermined backing material. The backing layer 47 is bonded and laminated along the backing layer-side glass fiber mat 43 by an adhesive film 46 so as to face the resin-impregnated semi-rigid foamed urethane layer 41 via the backing layer-side glass fiber mat 43. The predetermined backing material mentioned above is, for example, polyester nonwoven fabric. In this first embodiment, the total basis weight and total thickness of the sunshade 40 are, for example, 1430 g / m². 2 And it is 7.0 mm.

[0089] As shown in Figures 6 and 7, the stacked sunshade 40 is composed of a flat central portion 40d, front and rear side ends 40e, 40f, and left and right side edges 40g, 40h. When the sunshade 40 is formed by press molding as described above, it is compressed into a predetermined three-dimensional flat shape having the front and back surface shapes shown in Figures 6 and 7 and the vertical cross-sectional shape shown in Figure 8.

[0090] In this first embodiment, Figure 6 is a view of the sunshade 40 from its surface (the side of the vehicle interior of the vehicle body 10). On the other hand, Figure 7 is a view of the sunshade 40 from its back surface (the side of the sunroof 20). The surface of the outer layer 45 of the sunshade 40 (the side of the vehicle interior of the vehicle body 10) is referred to as the surface of the sunshade 40, and the back surface of the inner layer 47 of the sunshade 40 (the side of the sunroof 20) is referred to as the back surface of the sunshade 40.

[0091] Here, the front and rear end portions 40e, 40f and the left and right edge portions 40g, 40h are compressed and formed at a higher compression ratio than the flat central portion 40d. Therefore, the front and rear end portions 40e, 40f and the left and right edge portions 40g, 40h have higher rigidity and are harder than the flat central portion 40d. In this first embodiment, the compression ratios of the front and rear end portions 40e, 40f may be the same as the compression ratios of the left and right edge portions 40g, 40h, or they may be higher or lower than the compression ratios of the left and right edge portions 40g, 40h.

[0092] In the sunshade 40, of the front and rear end portions 40e and 40f, the front end portion 40e extends forward from the front end of the flat central portion 40d, as shown in any of Figures 5 to 7. On the other hand, the rear end portion 40f extends from the rear end of the flat central portion 40d and is formed to protrude in a U-shape toward the backing material member 40c, as shown in Figure 5. In this first embodiment, the rear end portion 40f is also called the rear locking portion 40f. When the sunshade device SD reaches the rear sliding end, the rear locking portion 40f locks onto the rear inner edge of the inner plate opening, restricting further rearward sliding of the sunshade device SD.

[0093] The left and right side edges 40g and 40h correspond to the left and right side edges of the sunshade 40, and as shown in Figures 6 and 7, these left and right side edges 40g and 40h are formed to extend outward in opposite directions from the left and right side edges of the flat central portion 40d.

[0094] Here, the left edge portion 40g has front and rear notches j (see Figure 6) for attaching each of the two sliding members 60 (described later), and these front and rear notches j are formed in a U-shape on both the front and rear sides of the left edge portion 40g. On the other hand, the right edge portion 40h has front and rear notches j (see Figure 6) for attaching the remaining two sliding members 60, and these front and rear notches j are formed in a U-shape on both the front and rear sides of the right edge portion 40h.

[0095] The knob 50 is fitted into a narrow through-hole portion h (see Figures 6 to 8) formed in the central left-right portion of the front end of the flat central portion 40d (see Figures 3 to 5). Here, the knob 50 is formed in a concave shape so as to be recessed from the surface layer 45 side to the back layer 47 side, so that it can be fitted into the narrow through-hole portion h of the flat central portion 40d.

[0096] However, crew But by With the operation of knob 50, the car Body 10 inside the car In this case, through the inner plate opening, Nsha 40 Before By sliding along the left and right guide rails 30 in the rearward direction, the sunshade device SD slides along the guide rail device 30 in the front-rear direction. When the sunshade device SD is at the front sliding end, the sunshade device SD closes the window WD with its sunshade 40. When the sunshade device SD is at the rear sliding end, the sunshade device SD opens the window WD with its sunshade 40. When the sunshade device SD closes the window WD, the sunshade 40 is in the closed state, and when the sunshade device SD opens the window WD, the sunshade 40 is in the open state.

[0097] The four sliding members 60 are each assembled in pairs to the front and rear sides of the left edge 40g and the right edge 40h of the sunshade 40, as can be seen in Figures 3 and 4. This means that the sunshade device SD is supported on the outer plate 21 so as to be slidable in the front-rear direction via the left and right guide rails 30, along with the four sliding members 60 in the sunshade 40 (see Figures 1-4, 6 and 7). In this first embodiment, of the four sliding members 60, the two sliding members 60 attached to the front and rear sides of the left edge portion 40g of the sunshade 40 are referred to as the left front sliding member 60 and the left rear sliding member 60. Also, the two sliding members 60 attached to the front and rear sides of the right edge portion 40h of the sunshade 40 are referred to as the right front sliding member 60 and the right rear sliding member 60.

[0098] In detail, the left front sliding member 60 is attached to a front notch j (see Figure 6) formed on the left edge 40g of the sunshade 40, and the left rear sliding member 60 is attached to a rear notch j (see Figure 6) formed on the left edge 40g of the sunshade 40. Furthermore, the right front sliding member 60 is attached to a right notch j (see Figure 6) formed on the right edge 40h of the sunshade 40, and the right rear sliding member 60 is attached to a rear notch j (see Figure 6) formed on the right edge 40h of the sunshade 40. All four sliding members 60 have the same configuration.

[0099] In this first embodiment configured as described above, the core member 40a of the sunshade 40 is formed of two glass fiber mats 42 and 43 and a resin-impregnated semi-rigid foamed urethane layer 41 laminated between the two glass fiber mats 42 and 43, as described above.

[0100] In the core member 40a, the resin-impregnated semi-rigid foamed urethane layer 41 is formed by uniformly impregnating the entire semi-rigid foamed urethane layer 41a with liquid isocyanate and curing it, as described above.

[0101] Here, the basis weight of the liquid isocyanate impregnated into the semi-rigid foamed urethane layer 41a can be increased far more than the sum of the basis weights of the liquid isocyanate when impregnating each of the glass fiber mats 42 and 43, due to the structure of the semi-rigid foamed urethane layer 41a as described above. In other words, the basis weight of the isocyanate impregnated in the resin-impregnated semi-rigid foamed urethane layer 41 can be increased far more than the sum of the basis weights of the isocyanate that can be impregnated into each of the glass fiber mats 42 and 43.

[0102] According to this, the core member 40a has much higher rigidity than a core member consisting of two resin-impregnated glass fiber mats and a semi-rigid foamed urethane layer 41a, when each of the two glass fiber mats 42 and 43 is impregnated with liquid isocyanate and cured. Therefore, a board-type sunshade 40 equipped with the core member 40a can maintain its original board shape well. As a result, the sliding of the sunshade device SD in the front-rear direction along both guide rails 30 can be made even smoother than that of conventional sunshade devices.

[0103] As described above, in this first embodiment, the core member 40a of the sunshade 40 is composed of a laminate consisting of a glass fiber mat 42 on the surface layer side, a resin-impregnated semi-rigid foamed urethane layer 41, and a glass fiber mat 43 on the back layer side, as described above.

[0104] In this laminate, the resin-impregnated semi-rigid foamed urethane layer 41 is formed by uniformly impregnating the semi-rigid foamed urethane layer 41a with liquid isocyanate and curing it, without requiring curing for impregnation, unlike glass fiber mats 42 and 43 made of glass fibers that are difficult to impregnate with liquid isocyanate.

[0105] Incidentally, in order to test the bending strength of the sunshade 40 molded as described above, a sample of the sunshade 40 was prepared, and the bending strength of the sample was tested using a bending strength testing device.

[0106] The specimen in question is formed with a configuration corresponding to the flat central portion 40d of the sunshade 40. For example, the specimen is formed to have a flat plate shape consisting of a width of 50 mm, a length of 150 mm, and a total thickness of 7.0 mm.

[0107] Furthermore, the basis weight of the liquid isocyanate impregnating the semi-rigid polyurethane foam layer of the sample is 200 g / m². 2 The basis weight of the glass fiber mat on the surface layer and the glass fiber mat on the underside layer of the sample was 300 g / m². 2 That is the case.

[0108] Furthermore, for the bending strength test, a sample having the same configuration as the flat central portion of a conventional sunshade was prepared as a comparative sample. This conventional sunshade has a surface member 40b and a backing member 40c of the sunshade 40, as well as a core member different from the core member 40a of the sunshade 40.

[0109] The core member of the conventional sunshade is composed of a resin-impregnated glass fiber mat on the surface layer side, a semi-rigid foamed urethane layer 41a, and a resin-impregnated glass fiber mat on the back layer side, corresponding to the glass fiber mat 42 on the surface layer side, the resin-impregnated semi-rigid foamed urethane layer 41, and the glass fiber mat 43 on the back layer side of the sunshade 40.

[0110] Here, the surface layer side resin-impregnated glass fiber mat and the back layer side resin-impregnated glass fiber mat are formed by impregnating and curing liquid isocyanate throughout the entire surface layer side glass fiber mat 42 and the back layer side glass fiber mat 43 of the sunshade 40, respectively. The amount of liquid isocyanate impregnated into each of the surface layer side resin-impregnated glass fiber mat and the back layer side resin-impregnated glass fiber mat is 50 g / m². 2 ±5g / m 2 A value within (for example, 30 g / m²) 2 ) Furthermore, the comparative sample is formed to have a flat plate shape consisting of a width of 50 mm, a length of 150 mm, and a total thickness of 7.0 mm, similar to the experimental sample described above.

[0111] Furthermore, as shown in Figure 12, the bending strength testing apparatus has two support elements 80a and 80b and a load element 80c. As shown in Figure 19, the two support elements 80a and 80b are arranged with a horizontal gap between them, and the horizontal gap between the support points 81 and 82 of the two support elements 80a and 80b is set to 100 mm.

[0112] Furthermore, the load element 80c is supported so as to be able to move up and down at an intermediate position between the two support elements 80a and 80b, and the load element 80c faces the intermediate position between the support points 81 and 82 of the two support elements 80a and 80b at its lower end 83. The horizontal distance between each of the support points 81 and 82 and the lower end 83 of the load element 80c is 50 mm (see Figure 12).

[0113] When performing a bending strength test on a set sample T using a bending strength testing apparatus configured in this manner, the set sample T is set on the respective support points 81 and 82 so as to span both support elements 80a and 80b, as shown in Figure 12.

[0114] In this setup, when the load element 80c is moved downward toward the midpoint between the two support points 81 and 82, the load element 80c applies a downward load toward the left-right center of the set sample T at its lower end 83. As a result, the maximum load applied to the set sample T and the bending elastic gradient when this maximum load is applied to the set sample T can be measured by the bending strength testing apparatus as the bending strength characteristics of the set sample T.

[0115] Then, the above-mentioned comparative sample was set as set sample T on the respective support points 81 and 82 of both support elements 80a and 80b in the same manner as described above, and a load was applied to the comparative sample using the loader 80c in the same manner as described above. As a result, the bending strength characteristics of the comparative sample were obtained as a maximum bending strength of 48 N and a bending elastic gradient of 115 N / cm, as shown in the table in Figure 11.

[0116] On the other hand, the above-mentioned test specimen was set as set specimen T and placed on the respective support points 81 and 82 of both support elements 80a and 80b in the same manner as described above, and a load was applied to the test specimen using the loader 80c in the same manner as described above. As a result, the bending strength characteristics of the test specimen were obtained as a maximum bending strength of 70 N and a bending elastic gradient of 220 N / cm, as shown in the table in Figure 11.

[0117] Comparing these bending strength characteristics, it can be seen that the maximum load on the above-mentioned sample is approximately 1.5 times the maximum load on the above-mentioned comparison sample. Furthermore, in this case, it can be seen that the bending elastic gradient of the above-mentioned sample is approximately twice that of the above-mentioned comparison sample.

[0118] Therefore, it can be seen that the bending strength characteristics of the test sample are significantly improved compared to the bending strength characteristics of the comparative sample. In other words, it can be seen that the sunshade 40 manufactured in this first embodiment has much higher rigidity than conventional sunshades.

[0119] Furthermore, in this first embodiment, by making the target of liquid isocyanate impregnation a semi-rigid foamed urethane layer 41a, as described above, the amount of liquid isocyanate impregnated can be set to an amount that allows for further strengthening of the rigidity of the sunshade 40, for example, 200 g / m². 2 The amount can be increased up to that point. As a result, as can be seen from the bending strength test results described above, the rigidity of the core member 40a, and by extension the sunshade 40, can be significantly improved compared to the case where liquid isocyanate is impregnated into both glass fiber mats 42 and 43. (Second Embodiment) Figure 13 shows the main parts of a second embodiment of the sunshade device according to the present invention. In this second embodiment, the sunshade device is equipped with a sunshade shown in Figures 13 and 14 (hereinafter referred to as sunshade 40 in this second embodiment as well) instead of sunshade 40 in the sunshade device SD referred to in the first embodiment. The sunshade device referred to in this second embodiment is also denoted by the reference numeral SD, similar to the sunshade device SD referred to in the first embodiment.

[0120] The sunshade 40 in this second embodiment comprises the outer skin member 40b and the inner skin member 40c described in the first embodiment, as well as a core member 40m that replaces the core member 40a (see Figures 13 and 14). The core member 40m is laminated between the outer skin member 40b and the inner skin member 40c.

[0121] The core member 40m comprises the resin-impregnated semi-rigid foamed urethane layer 41 described in the first embodiment, and also comprises a resin-impregnated glass fiber mat 48 on the surface layer side and a resin-impregnated glass fiber mat 49 on the back layer side, which replace the glass fiber mat 42 on the surface layer side and the glass fiber mat 43 on the back layer side, respectively, as described in the first embodiment. In this second embodiment, the resin-impregnated semi-rigid foamed urethane layer 41 is laminated between the resin-impregnated glass fiber mat 48 on the surface layer side and the resin-impregnated glass fiber mat 49 on the back layer side (see Figure 14).

[0122] The surface layer side resin-impregnated glass fiber mat 48 is formed by uniformly impregnating and curing liquid isocyanate over the entire surface layer side glass fiber mat 42 described in the first embodiment. On the other hand, the back layer side resin-impregnated glass fiber mat 49 is formed by uniformly impregnating and curing liquid isocyanate over the entire back layer side glass fiber mat 43 described in the first embodiment.

[0123] In this second embodiment, the basis weight of the liquid isocyanate impregnated into the surface layer-side glass fiber mat 42 to form the surface layer-side resin-impregnated glass fiber mat 48 is a value within a predetermined basis weight range, for example, 30 g / m². 2 It is set to the following. On the other hand, the basis weight of the liquid isocyanate impregnated into the glass fiber mat 43 on the backing layer side in order to form the resin-impregnated glass fiber mat 49 on the backing layer side is also set to a value within the predetermined basis weight range, for example, 30 g / m². 2 It is set to this. Accordingly, the total basis weight and total thickness of the sunshade 40 in this second embodiment are, for example, 1290 g / m². 2 And it is 7.0 mm.

[0124] In this second embodiment, the predetermined basis weight range, which is the range of basis weights of the liquid isocyanate impregnated into the surface layer side glass fiber mat 42 and the back layer side glass fiber mat 43 in order to form the surface layer side resin-impregnated glass fiber mat 48 and the back layer side resin-impregnated glass fiber mat 49 described above, is 20 g / m². 2 ~50g / m 2It is set to this.

[0125] Within the specified weight range, the lower limit is 20 g / m². 2 This was because it was 20g / m 2 Below this level, it would result in insufficient rigidity as a resin-impregnated glass fiber mat. On the other hand, the upper limit is 50 g / m². 2 This was because of the 50g / m² 2 This is because, due to its composition, it is difficult to impregnate the glass fiber mat beyond a certain amount. The basis weight of the liquid isocyanate impregnating the surface layer glass fiber mat 42 and the back layer glass fiber mat 43 is 30 g / m². 2 ±3g / m 2 A value within the range, for example, 30 g / m 2 That's fine.

[0126] However, in the sunshade 40 of this second embodiment, the core member 40m configured as described above is laminated between the outer skin member 40b and the inner skin member 40c, as shown in Figure 14. Under this lamination, the sunshade 40 is compression-molded to have the cross-sectional shape shown in Figure 13. The other configurations of the sunshade device of this second embodiment are the same as those of the first embodiment described above.

[0127] In the sunshade 40 of this second embodiment, which is configured as described above, the core member 40m employs two resin-impregnated glass fiber mats 48 and 49, unlike the two glass fiber mats 42 and 43 of the core member 40a described in the first embodiment. Furthermore, the core member 40m is formed by laminating the resin-impregnated semi-rigid foamed urethane layer 41 described in the first embodiment between the two resin-impregnated glass fiber mats 48 and 49.

[0128] Therefore, the core member 40m in this second embodiment has total rigidity, which is obtained by adding the rigidity of both resin-impregnated glass fiber mats 48 and 49 to the rigidity of the resin-impregnated semi-rigid foamed urethane layer 41 described in the first embodiment.

[0129] As a result, the sunshade 40 in this second embodiment can be made even more rigid than the sunshade 40 in the first embodiment, based on the total rigidity of the core member 40m. This means that the original board shape of the sunshade 40 in this second embodiment (see Figure 13) can be maintained even better than that of the sunshade 40 in the first embodiment. Other effects and advantages of this second embodiment are the same as those of the first embodiment. (Third embodiment) Figure 15 shows a third embodiment of the automobile sunshade device according to the present invention. The sunshade device in this third embodiment has a configuration in which the board-type sunshade 40 of the sunshade device SD described in the first embodiment is equipped with a front end 40i, a left edge 40j, and a right edge 40k instead of the front end 40e, left edge 40g, and right edge 40h. The sunshade device in this third embodiment is also denoted by the reference numeral SD, similar to the sunshade device SD in the first embodiment.

[0130] Furthermore, the sunshade device SD referred to in this third embodiment has a configuration that includes a left rear sliding member 70 and a right rear sliding member 70 in place of the left rear sliding member 60 and the right rear sliding member 60 in the sunshade device SD described in the first embodiment. In this third embodiment, the left front sliding member 60 and the right front sliding member 60 described in the first embodiment are not used.

[0131] First, this third implementation form In a state The configuration of the front end portion 40i of the board-type sunshade 40 will now be described. As shown in any of Figures 15 to 17, when the front end portion 40i is compression-molded at a compression ratio higher than that of the flat central portion 40d described in the first embodiment, it is heated and compressed in conjunction with the compression molding so that it protrudes from the front end portion of the flat central portion 40d toward its front in a gently convex curved shape and curves toward the backing material member 40c.

[0132] Next, the configurations of the left and right side edges 40j and 40k of the board-type sunshade 40 in this third embodiment will be described. Of the left and right side edges 40j and 40k, the left side edge 40j is formed to extend to the left from the left side of the flat central portion 40d, similar to the left side edge 40g described in the first embodiment (see Figure 15). Figure 15 shows the sunshade 40 as viewed from the back side (the side of the roof of the automobile).

[0133] The left edge portion 40j is compression-molded at its longitudinal middle portion j1 ​​and longitudinal rear portion j2 with the same compression ratio as the left edge portion 40g described in the first embodiment (see Figure 17). Furthermore, the longitudinal front portion j3 of the left edge portion 40j is compression-molded as a left support portion (hereinafter also referred to as the left support portion j3) with a lower compression ratio than that of the longitudinal middle portion j1 ​​and longitudinal rear portion j2, for example, the same compression ratio as that of the flat central portion 40d (see Figures 15 and 17).

[0134] This means that the shape of the left support portion j3 is more bulging (expanded) than the shapes of the longitudinal middle portion j1 ​​and the longitudinal rear portion j2. The left support portion j3 serves as a substitute for the left front sliding member 60 described in the first embodiment above.

[0135] Here, the left support portion j3 is formed to be offset below the flat central portion 40d (towards the surface member 40b) as shown in Figure 18. Accordingly, the left support portion j3 is located below the longitudinal central portion j1 ​​of the left edge portion 40j as shown in Figure 18, on the surface member 40b side, while the left support portion j3 is located above the longitudinal central portion j1 ​​of the left edge portion 40j as shown in Figure 18, on the back surface member 40c side. In addition, a notch portion j4 (see Figures 15 and 17) similar to the notch portion j described in the first embodiment is formed in the longitudinal rear portion j2.

[0136] On the other hand, the right edge portion 40k is compression-molded at the same compression ratio as the right edge portion 40h described in the first embodiment, at its longitudinal middle portion k1 and longitudinal rear portion k2. Furthermore, the longitudinal front portion k3 of the right edge portion 40k is compression-molded at the same compression ratio as the longitudinal middle portion k1 and longitudinal rear portion k2. A compression ratio lower than the rate, For example, the right support portion (hereinafter also referred to as the right support portion k3) is compression-molded with the same compression ratio as the flat central portion 40d. This means that the shape of the right support portion k3 is more bulging (bulged shape) than the shapes of the longitudinal central portion k1 and the longitudinal rear portion k2. The right support portion k3 serves as a substitute for the right front sliding member 60 described in the first embodiment above.

[0137] Here, the right support portion k3 is formed to be positioned lower than the flat central portion 40d, similar to the left support portion j3. Accordingly, the right support portion k3 is located below the longitudinal central portion k1 of the right edge portion 40k, similar to the outer surface member 40b portion of the left support portion j3, on the outer surface member 40b side, while the right support portion k3 is located above the longitudinal central portion k1 of the right edge portion 40k, similar to the inner surface member 40c portion of the left support portion j3. A notch k4 (see Figure 15), similar to the notch j described in the first embodiment, is formed in the longitudinal rear portion k2.

[0138] Next, the configurations of the left rear sliding member 70 and the right rear sliding member 70 in this third embodiment will be described. Of the left rear sliding member 70 and the right rear sliding member 70, the left rear sliding member 70 is attached to a notch j4 (see Figure 19) formed in the rear portion j2 of the left edge 40j of the sunshade 40, while the right rear sliding member 70 is attached to a notch k4 (see Figure 15) formed in the rear portion k2 of the right edge 40k of the sunshade 40.

[0139] Since the left rear sliding member 70 and the right rear sliding member 70 both have the same configuration, the configuration of the left rear sliding member 70 will be described below using it as an example. As shown in Figures 19 and 20, the left rear sliding member 70 comprises a member body 70a and a mounting plate 70b. The member body 70a has a bottom plate portion 71, and the bottom plate portion 71 sandwiches the longitudinal rear portion j2 of the left edge portion 40j between itself and the mounting plate 70b (see Figure 20).

[0140] The clamping is performed as follows. Specifically, the bottom plate portion 71 is fitted into a pair of through holes j5 in the longitudinal rear portion j2 (only one through hole j5 is shown in Figure 20) at its pair of bifurcated portions 71a (only one bifurcated portion 71a is shown in Figure 20) (see Figure 15). The pair of bifurcated portions 71a are formed to protrude from the bottom plate portion 71 toward the mounting plate 70b, corresponding to the pair of through holes j5 in the longitudinal rear portion j2.

[0141] On the other hand, the mounting plate 70b engages with the pair of bifurcated portions 71a of the bottom plate portion 71 at the inside of the pair of through holes j5 in the longitudinal rear portion j2, through its pair of projections 72 (only one projection 72 is shown in Figure 20). This provides the clamping described above. The pair of projections 72 are formed to protrude from the mounting plate 70b toward the bottom plate portion 71 so as to face the pair of through holes j5 in the longitudinal rear portion j2.

[0142] Furthermore, the member body 70a comprises a longitudinal case portion 73, a pair of sliding contact pieces 74, a spring piece 75, and a pair of elastic pieces 76, as shown in either Figure 19 or Figure 20. The longitudinal case portion 73 is integrally formed with the bottom plate portion 71 at its bottom wall portion 73a, as shown in Figure 20, and the longitudinal case portion 73 engages with the left end of the mounting plate 70b at its L-shaped wall portion 73b, as shown in Figure 20, thereby maintaining the aforementioned clamping between the mounting plate 70b and the bottom plate portion 71.

[0143] As shown in Figure 19, the pair of sliding contact pieces 74 are housed within the case portion 73 via a spring piece 75, and the pair of sliding contact pieces 74 are biased by the spring piece 75 toward the upper wall portion (hereinafter referred to as the upper wall portion 31) of the guide rail 30. As a result, the pair of sliding contact pieces 74 slide against the inner surface of the upper wall portion 31 of the guide rail 30.

[0144] Here, the spring piece 75 is interposed between the lower wall portion (hereinafter referred to as the lower wall portion 32) of the guide rail 30 and the pair of sliding contact pieces 74, and the spring piece 75 biases the pair of sliding contact pieces 74 toward the upper wall portion 31 of the guide rail 30. The pair of elastic pieces 76 are provided projecting from the outer surface of the bottom wall portion 33 (see Figure 20) of the guide rail 30 at intervals in the longitudinal direction of the case portion 73. As a result, the pair of elastic pieces 76 elastically contact the inner surface of the bottom wall portion 33 of the guide rail 30. The right rear sliding member 70 is also constructed with the same components as the left rear sliding member 70.

[0145] As described above, the left and right support portions j3 and k3 (see Figure 15) and the left and right rear sliding members 70 (see Figure 15) are provided on the sunshade 40. Here, on the left edge portion 40j of the sunshade 40, the left support portion j3, which is the longitudinal front portion j3, is compressed and formed such that its compression ratio is lower than that of the longitudinal central portion j1 ​​and the longitudinal rear portion j2 of the left edge portion 40j of the sunshade 40, and has a shape that is more bulging than the shape of the longitudinal central portion j1 ​​and the longitudinal rear portion j2 (bulged shape).

[0146] Furthermore, in the sunshade 40, the right support portion k3, which is the longitudinal front portion k3 of the right edge portion 40k, is compressed and formed such that its compression ratio is lower than that of the longitudinal central portion k1 and the longitudinal rear portion k2 of the right edge portion 40k of the sunshade 40, and has a shape that is more bulging than the shapes of the longitudinal central portion k1 and the longitudinal rear portion k2 (bulged shape).

[0147] Furthermore, the left rear sliding member 70 is in sliding contact with the lower wall portion 32 and upper wall portion 31 of the left guide rail 30 at the bottom wall portion 73a of its case portion 73 and a pair of sliding contact pieces 74, under the biasing force of the spring piece 75.

[0148] With the above configuration, the left edge portion 40j of the sunshade 40 can be lifted from the inner surfaces of the upper wall portion 31 and the lower wall portion 32 of the left guide rail 30, with its longitudinal central portion j1 ​​and longitudinal rear portion j2 floating above the inner surfaces of the upper wall portion 31 and the lower wall portion 32 of the right edge portion 40k of the sunshade 40.

[0149] As a result, the left and right side edges 40j and 40k of the sunshade 40, together with the left and right rear sliding members 70, slide against the left and right side guide rails 30 only by the left and right side support parts j3 and k3. Therefore, when opening and closing the sunshade device SD, the sunshade device SD can always be opened and closed with sliding resistance that allows for smooth operation. The other configurations of the sunshade device SD in this third embodiment are the same as those of the first embodiment described above.

[0150] As described above, in this third embodiment, in the board-type sunshade 40, when the front end portion 40i is heat-compressed and molded at a compression ratio higher than that of the flat central portion 40d as described in the first embodiment, it is heat-compressed and molded in conjunction with the compression molding so that it protrudes from the front end portion of the flat central portion 40d toward the front in a gently convex curved shape toward the back skin member 40c side. At this time, the front end portion 40e is fused together by heat compression from the surface skin member 40b side toward the back skin member 40c side during the heat-compression molding process.

[0151] Therefore, at the front end portion 40i of the sunshade 40, the core member 40a is not exposed from the front end portion 40i to the surface member 40b. As a result, even when the sunshade 40 is viewed from the surface layer 45 side, the end face of the core member 40a is not visible, and a good aesthetic appearance can be ensured when viewed from the front end portion 40i of the sunshade 40.

[0152] Furthermore, as described above, the front end portion 40i of the sunshade 40 is heat-compressed and molded to curve toward the backing material 40c side, protruding gently in a convex curve from the front end portion of the flat central portion 40d toward the front. Moreover, in the core member 40a, the resin-impregnated semi-rigid foamed urethane layer 41, which is laminated between the glass fiber mats 42 and 43 on both sides, is formed by impregnating the semi-rigid foamed urethane layer 41a with liquid isocyanate throughout and hardening it during the heat-compression molding described above, as explained in the first embodiment.

[0153] In this case, due to the structure of the semi-rigid foamed urethane layer 41a, the basis weight of the liquid isocyanate impregnated into the semi-rigid foamed urethane layer 41a is significantly increased compared to the total basis weight of the liquid isocyanate when impregnating the glass fiber mats 42 and 43 on both sides, as described in the first embodiment above. Consequently, the rigidity of the front end portion 40i of the sunshade 40 is further increased.

[0154] Therefore, even when the operator's hand presses against the front end 40i during the opening and closing operation of the sunshade 40, the front end 40i can maintain its original shape without any deformation. Other effects are the same as those of the first embodiment described above.

[0155] In implementing the present invention, various modifications are possible, not limited to the embodiments described above. (1) In carrying out the present invention, the sunshade device SD described in the first embodiment may be replaced with the sunshade device SD described in the second embodiment, and the third embodiment may be applied to it.

[0156] In this case, the core member 40m is configured to include both resin-impregnated glass fiber mats 48 and 49 in addition to the resin-impregnated semi-rigid foamed urethane layer 41. Therefore, the rigidity of the core member 40m can be further improved compared to the third embodiment described above.

[0157] Accordingly, the rigidity of the front end portion 40i of the sunshade 40 can also be further improved. As a result, the effects of the third embodiment described above can be further enhanced by the further improvement in rigidity. (2) In carrying out the present invention, the resin impregnated into the resin-impregnated semi-rigid foamed urethane layer described in the first or second embodiment above is not limited to liquid isocyat, but may be any thermosetting resin such as urethane. (3) In carrying out the present invention, the resin impregnated into the resin-impregnated glass fiber mat described in the second embodiment above is not limited to liquid isocyat, but may be any thermosetting resin such as urethane. (4) In carrying out the present invention, the surface skin member 40b described in the first embodiment may be replaced with an adhesive layer such as a simple adhesive film laminated on the surface skin layer 45 instead of the barrier film 44. Also, the back skin member 40c described in the first embodiment may be not limited to an adhesive film 46, but may be an adhesive layer laminated on the back skin layer 47.

Claims

1. A board-type sunshade comprising an outer skin member, an inner skin member, and a core member laminated between the outer skin member and the inner skin member, The core member is A first resin-impregnated glass fiber mat is formed by impregnating a glass fiber mat with a liquid thermosetting resin throughout and curing it, A second resin-impregnated glass fiber mat is formed by impregnating a glass fiber mat with a liquid thermosetting resin throughout and curing it, It comprises a resin-impregnated semi-rigid foamed urethane layer formed by impregnating the entire semi-rigid foamed urethane layer with a liquid thermosetting resin and curing it, The resin-impregnated semi-rigid polyurethane foam layer is laminated between the first and second resin-impregnated glass fiber mats. The liquid thermosetting resin impregnated into each of the first and second resin-impregnated glass fiber mats has a basis weight within the range of 20 g / m² to 50 g / m², which is a first predetermined basis weight range. The liquid thermosetting resin impregnated into the resin-impregnated semi-rigid foamed urethane layer has a basis weight within a second predetermined basis weight range of 100 g / m² to 500 g / m², which is a board-type sunshade.

2. The aforementioned skin member consists of a skin layer and an adhesive layer on the skin layer side. The aforementioned backing member consists of a backing layer and a backing layer-side adhesive layer. The board-type sunshade according to claim 1, wherein in the core member, one of the first and second resin-impregnated glass fiber mats is bonded to the surface layer by the surface layer side adhesive layer so as to face the surface layer via the surface layer side adhesive layer, while the other of the first and second resin-impregnated glass fiber mats is bonded to the back layer by the back layer side adhesive layer so as to face the back layer via the back layer side adhesive layer.

3. The board-type sunshade according to claim 1, characterized in that the liquid thermosetting resin is a liquid isocyanate.

4. A sunshade device applied to the sunroof of an automobile body, The sunshade comprises a board-type sunshade consisting of an outer skin member, an inner skin member, and a core member laminated between the outer skin member and the inner skin member, and a plurality of sliding members attached to at least the rear portions of both left and right side edges of the board-type sunshade. The sunroof is formed by an outer panel and an inner panel located inside the outer panel. The outer panel has an outer panel opening formed to form the window of the sunroof, and the inner panel has an inner panel opening formed to face the outer panel opening. The board-type sunshade is supported on the outer panel so as to be slidable in the front-rear direction via left and right side guide rails, which are arranged in the front-rear direction along the left and right sides of the openings of the outer panel and the openings of the inner panel, together with the plurality of sliding members between the outer panel and the inner panel. In the aforementioned board-type sunshade, the core member is A first resin-impregnated glass fiber mat is formed by impregnating a glass fiber mat with a liquid thermosetting resin throughout and curing it, A second resin-impregnated glass fiber mat is formed by impregnating a glass fiber mat with a liquid thermosetting resin throughout and curing it, It comprises a resin-impregnated semi-rigid foamed urethane layer formed by impregnating the entire semi-rigid foamed urethane layer with a liquid thermosetting resin and curing it, The resin-impregnated semi-rigid polyurethane foam layer is laminated between the first and second resin-impregnated glass fiber mats. In each of the first and second resin-impregnated glass fiber mats, the liquid thermosetting resin impregnated into the glass fiber mat has a basis weight within a first predetermined basis weight range of 20 g / m² to 50 g / m². An automobile sunshade device in which, in the resin-impregnated semi-rigid foamed urethane layer, the liquid thermosetting resin impregnated into the semi-rigid foamed urethane layer has a basis weight within a second predetermined basis weight range of 100 g / m² to 500 g / m².

5. A sunshade device applied to the sunroof of an automobile body, It comprises a board-type sunshade and multiple sliding members. The sunroof is formed by an outer panel and an inner panel located inside the outer panel. The outer panel has an outer panel opening formed to form the window of the sunroof, and the inner panel has an inner panel opening formed to face the outer panel opening. The board-type sunshade is formed from a laminate comprising a surface member, a backing member, and a core member laminated between the surface member and the backing member, and has a flat central portion, front and rear side ends extending from the flat central portion to both the front and rear sides and formed by compression at a higher compression ratio than the flat central portion, and left and right side edges extending from the flat central portion to both the left and right sides. Of the aforementioned front and rear ends, the front end is further formed to curve toward the backing material with a gently convex curved shape toward the front. Each of the left and right side edges comprises a front portion and the remaining portion excluding the front portion, which is formed by compression at a higher compression ratio than that of the flat central portion. Each of the front portions of the left and right side edges is formed by compression at a lower compression ratio than that of the remaining portion. In the aforementioned board-type sunshade, the core member is A first resin-impregnated glass fiber mat is formed by impregnating a glass fiber mat with a liquid thermosetting resin throughout and curing it, A second resin-impregnated glass fiber mat is formed by impregnating a glass fiber mat with a liquid thermosetting resin throughout and curing it, It comprises a resin-impregnated semi-rigid foamed urethane layer formed by impregnating the entire semi-rigid foamed urethane layer with a liquid thermosetting resin and curing it, The resin-impregnated semi-rigid polyurethane foam layer is laminated between the first and second resin-impregnated glass fiber mats. In each of the first and second resin-impregnated glass fiber mats, the liquid thermosetting resin impregnated into the glass fiber mat has a basis weight within a first predetermined basis weight range of 20 g / m² to 50 g / m². In the resin-impregnated semi-rigid foamed urethane layer, the liquid thermosetting resin impregnated into the semi-rigid foamed urethane layer has a basis weight within a second predetermined basis weight range of 100 g / m² to 500 g / m². The plurality of sliding members are attached to at least the rear portions of the left and right side edges of the board-type sunshade. The board-type sunshade is an automotive sunshade device supported on the outer panel so as to be slidable in the front-rear direction via left and right side guide rails, which are arranged in the front-rear direction along the left and right sides of the openings of the outer panel and the openings of the inner panel, together with the plurality of sliding members between the outer panel and the inner panel.

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