A planar backing material and a method for manufacturing a vehicle molded material equipped with the planar backing material.

Abstract

To provide a planar backing capable of adhering a molding material for a vehicle with a three-dimensional shape to a vehicle panel, and a method for manufacturing the molding material for a vehicle provided with the planar backing.SOLUTION: A molding material 1 for a vehicle includes a base material layer 2 including a core material 5 and fiber reinforcing layers 6 and 7 laminated on the core material 5 via a thermosetting resin 13, and a planar backing 3 facing in between the base material layer 2 and a vehicle panel P. The planar backing 3 has a nonwoven fabric layer 16, a bonding layer 9 laminated on the side of the vehicle body panel P of the nonwoven fabric layer 16, and a peeling layer 10 laminated on the bonding layer 9 and peelable from the bonding layer 9. A manufacturing method of the molding material 1 for a vehicle includes a lamination step of laminating the planar backing 3 on the base material layer 2, and a press-molding step of heating and pressurizing the laminated base material layer 2 and planar backing 3 with a press mold to be joined and integrated as one body, and molding into a surface shape along a surface of vehicle panel P.SELECTED DRAWING: Figure 5

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a vehicle molded material provided with a planar backing material and the planar backing material.

Background Art

[0002] Conventionally, a structure in which various core materials are bonded to a ceiling panel or the like of a vehicle body for purposes such as vibration damping, sound insulation, and heat insulation is known. For example, there is a structure in which a core material such as felt is attached to a ceiling panel with a double-sided tape. However, in a structure in which a core material is attached to a ceiling panel with a double-sided tape or the like, a gap is likely to occur between the vehicle body and the core material, and the performance such as sound insulation and heat insulation tends to deteriorate.

[0003] By the way, Patent Document 1 discloses an interior material sheet in which sheet materials are bonded together using an adhesive or an adhesive. The interior material sheet has an adhesive applied on one surface, and the gap between the bonding surfaces is small. As a method of applying an adhesive or the like to one surface of a sheet material, adhesive processing using a roll coater or the like is known.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] However, in adhesive processing using a roll coater, an adhesive is generally applied to a material in a flat state. Therefore, when the core material to be bonded to the inner surface of a vehicle body panel has a three-dimensional surface shape, it is difficult to perform adhesive processing by passing the molded body through the gap of a roll coater.

[0006] This invention was conceived in view of the above points, and the problem that this invention aims to solve is to provide a planar backing material that can evenly distribute a bonding agent in layers even on a three-dimensional surface shape, and a method for manufacturing a vehicle molding material equipped with the planar backing material. [Means for solving the problem]

[0007] One feature of a method for manufacturing a vehicle molding material that solves the above problems is that the vehicle molding material comprises a base material layer having a core material and a fiber reinforcement layer laminated on the core material via a thermosetting resin, and a planar backing material facing the base material layer between the base material layer and the vehicle body panel. The planar backing material comprises a nonwoven fabric layer, a bonding layer laminated on the vehicle body panel side of the nonwoven fabric layer, and a release layer laminated on the vehicle body panel side of the bonding layer and peelable from the bonding layer. The method for manufacturing the vehicle molding material includes a lamination step of laminating the planar backing material onto the base material layer, and a press molding step of joining the laminated base material layer and the planar backing material together by heating and pressurizing them in a press die, and forming them into a planar shape that conforms to the surface of the vehicle body panel.

[0008] One of the features and advantages of the above configuration is that a base material layer, in which a core material and a fiber reinforcement layer are laminated via a thermosetting resin, is laminated with a planar backing material having a bonding layer, and then heated and pressure-molded in a press die. Furthermore, a release layer is laminated to the bonding layer of the planar backing material. As a result, the base material layer and the planar backing material can be molded as a single unit without the bonding layer coming into contact with the press die during press molding. Through these processes, a three-dimensional planar shape vehicle molding material with a bonding layer evenly distributed across its surface can be molded without any post-processing after press molding.

[0009] The above method for manufacturing a molded material for vehicles may include a bonding layer formation step in which the bonding layer of the planar backing material is laminated onto the nonwoven fabric layer before the lamination step.

[0010] One of the features and advantages of the above configuration is that a bonding layer is formed on the flat, planar backing material before it is laminated onto the base layer. By forming a bonding layer on the planar backing material in advance during the process before molding the vehicle molding material, it is possible to easily obtain a vehicle molding material with a bonding layer compared to laminating the bonding layer onto a three-dimensional molded body.

[0011] One feature of the above-described planar backing material is a planar backing material for a vehicle molded material disposed between a vehicle body panel and a vehicle interior material, comprising: a nonwoven fabric layer laminated on the vehicle body panel side of a base material layer having a core material and a fiber reinforcement layer laminated on the core material via a thermosetting resin; a bonding layer laminated on the vehicle body panel side of the nonwoven fabric layer and capable of bonding the surface of the vehicle body panel and the vehicle molded material; and a release layer laminated on the vehicle body panel side of the bonding layer and capable of being peeled off from the bonding layer.

[0012] One of the features and advantages of the above configuration is that the planar backing material has a bonding layer laminated on a nonwoven fabric layer, which can be bonded to a vehicle body panel, and a release layer laminated on the vehicle body panel side of the bonding layer. As a result, the planar backing material and the base material layer can be press-molded as a single unit without the bonding layer coming into contact with the press die. In other words, by using a planar backing material with these features, it is possible to mold a three-dimensional surface-shaped vehicle molding material in which the bonding layer is evenly distributed across the entire surface. [Effects of the Invention]

[0013] The present invention provides a planar backing material that, by adopting the above configuration or manufacturing method, can evenly distribute a bonding agent in layers even on a three-dimensional surface shape, and a method for manufacturing a vehicle molding material equipped with the planar backing material. [Brief explanation of the drawing]

[0014] [Figure 1] This is a view from the rear of the passenger compartment showing the frame of the vehicle's ceiling and the vehicle-specific molded material attached to the ceiling panel. [Figure 2] This is a longitudinal cross-sectional view showing the material composition of a molding material for vehicles. [Figure 3]This is a schematic diagram illustrating the process of forming a bonding layer on a planar backing material. [Figure 4] This is a schematic diagram illustrating the process of laminating a planar backing material onto a base material layer. [Figure 5] This is a schematic diagram illustrating the process of forming vehicle molding materials using a press die. [Figure 6] This is a longitudinal cross-sectional view showing a press-formed molding material for vehicles. [Figure 7] This is a schematic diagram illustrating the process of bonding vehicle molding materials to vehicle body panels. [Modes for carrying out the invention]

[0015] <Composition of molding material for vehicles> Embodiments of the present invention will be described below with reference to the drawings. As a vehicle molding material according to this embodiment, a ceiling molding material 1 that is bonded to the ceiling panel P (vehicle body panel) of the vehicle body will be described. As shown in Figure 1, reinforcement members R are stretched across the ceiling panel P in the left-right direction of the vehicle body as reinforcing members. The number of reinforcement members R is set according to the required strength of the roof of the vehicle body. For example, the ceiling molding material 1 can be bonded to the ceiling panel P in areas demarcated by these reinforcement members R.

[0016] The ceiling molding material 1 is installed between the ceiling panel P and the ceiling interior material (not shown) in the thickness direction of the vehicle body ceiling. As shown in Figure 2, the ceiling molding material 1 has a base layer 2 and a planar backing material 3. The base layer 2 consists of a planar core material 5 and first and second fiber reinforcement layers 6 and 7 laminated on both sides of the core material 5 via a thermosetting adhesive 13 (thermosetting resin). The planar backing material 3 is laminated between the base layer 2 and the ceiling panel P, that is, facing the ceiling panel P side (upper side shown in Figure 2) of the first fiber reinforcement layer 6.

[0017] The core material 5 in the base material layer 2 is provided to maintain the shape and ensure the rigidity of the ceiling molding material 1, and is composed of a molded body having a surface shape along the surface of the ceiling panel P. The core material 5 according to the present embodiment is a urethane foam of a semi-rigid layer made of a urethane resin foam.

[0018] As shown in FIG. 2, a first fiber reinforcing layer 6 is laminated on the surface of the core material 5 on the ceiling panel P side, and a second fiber reinforcing layer 7 is laminated on the surface on the ceiling interior material side (the lower side shown in FIG. 2). The first and second fiber reinforcing layers 6 and 7 are provided to maintain the shape and ensure the rigidity of the ceiling molding material 1. These fiber reinforcing layers 6 and 7 are coated or impregnated with a thermosetting adhesive 13 on the surface, and are adhered to both surfaces of the core material 5, respectively. A glass fiber mat is selected for the first and second fiber reinforcing layers 6 and 7. The glass fiber mat is formed in a sheet shape by appropriately solidifying chopped strands obtained by cutting glass fibers, which are inorganic fibers, to an appropriate length with an appropriate binder.

[0019] These fiber reinforcing layers 6 and 7 may be those solidified with a binder without cutting the glass fibers (container mat). Alternatively, span lace, spunbond non-woven fabric, glass paper, or glass fiber woven fabric may be used. Also, the basis weight in the embodiment can be selected so as to conform to the required strength and other various conditions.

[0020] The fiber reinforcing material used for these fiber reinforcing layers 6 and 7 may be appropriately selected from inorganic fibers such as chopped strands, and natural fibers such as jute (corchorus capsularis), kenaf (hibiscus cannabinus), ramie, hemp (cannabis sativa), sisal hemp, bamboo, etc., which are organic fibers, and formed into a sheet shape or a mat shape by a binder such as acrylic or needle punching.

[0021] The thermosetting adhesive 13 is selected from a thermosetting resin, such as an isocyanate resin. Isocyanate is preferred from the viewpoint of being compatible with the core material 5, which is made of a semi-rigid urethane foam layer. Note that the thermosetting adhesive 13 is not limited to isocyanate resin and can be selected as appropriate. The thermosetting adhesive 13 is applied by spray, roll coater, etc. As described above, by laminating the fiber reinforcement layers 6, 7 containing thermosetting resin with the core material 5, the strength of the ceiling molding material 1 can be increased.

[0022] The planar backing material 3 has an intermediate layer 8 consisting of a thermoplastic bonding film layer 15 and a nonwoven fabric layer 16, a bonding layer 9, and a release layer 10. The bonding film layer 15 faces the surface of the base material layer 2 on the ceiling panel P side, i.e., the first fiber reinforcement layer 6. The nonwoven fabric layer 16 is laminated on the ceiling panel P side of the bonding film layer 15. For example, a polypropylene film is selected for the bonding film layer 15. The first fiber reinforcement layer 6 and the nonwoven fabric layer 16 are bonded by this bonding film layer 15. For example, a spunbond nonwoven fabric is selected for the nonwoven fabric layer 16. Spunbond nonwoven fabric is suitable because it has good adhesion to adhesives. Also, the nonwoven fabric is hardened with adhesive, which contributes to the rigidity of the ceiling molding material 1.

[0023] The bonding layer 9 is laminated on the ceiling panel P side of the nonwoven fabric layer 16. The bonding layer 9 adheres the ceiling molding material 1 to the ceiling panel P. For the bonding layer 9, for example, an acrylic adhesive is selected. The adhesive is applied to the surface of the nonwoven fabric layer 16 in the intermediate layer 8. For the bonding layer 9, spiral coating, adhesive, tape, etc., can be selected. Furthermore, a bonding agent whose properties do not change due to heat from hot pressing is preferred.

[0024] On the ceiling panel P side of the bonding layer 9, a release layer 10, consisting of a release paper that can be peeled off from the bonding layer 9, is laminated. The release layer 10 is selected from a sheet material that does not melt with the heat of the heat press, such as paper or film. By laminating the release layer 10 on the surface of the bonding layer 9, it is possible to prevent the adhesive and other components of the bonding layer 9 from coming into contact with and adhering to the press die 19 during the process of forming the ceiling molding material 1 with the press die 19 (see Figure 5). When the ceiling molding material 1 is bonded to the ceiling panel P, the bonding layer 9 and the surface of the ceiling panel P come into contact with each other with the release layer 10 peeled off.

[0025] A nonwoven fabric sheet 12 is laminated to the ceiling interior material side of the second fiber reinforcement layer 7. The nonwoven fabric sheet 12 prevents the exposure of glass fibers in the glass fiber mat and protects the surface of the second fiber reinforcement layer 7. For example, needle-punched nonwoven fabric is selected for the nonwoven fabric sheet 12. Depending on the material composition selected for the second fiber reinforcement layer 7, a configuration without the nonwoven fabric sheet 12 may also be used.

[0026] The ceiling molding material 1 may also be configured by laminating a heat-shielding film onto the surface (ceiling interior material side) of the nonwoven fabric sheet 12. For the heat-shielding film, for example, an aluminum vapor-deposited sheet can be selected. By providing a heat-shielding film, the temperature rise inside the vehicle can be further suppressed. Alternatively, instead of the nonwoven fabric sheet 12, the heat-shielding film may be directly laminated onto the second fiber reinforcement layer 7.

[0027] The ceiling molding material 1, with the above configuration, possesses a combination of properties including heat insulation, vibration damping, sound absorption and insulation, rigidity, and condensation reduction. The ceiling molding material 1 is joined to the surface of the ceiling panel P by a bonding layer 9. The ceiling molding material 1 can be bonded to the entire surface of the ceiling panel P after removing the reinforcement R. Since the ceiling molding material 1 has rigidity, the strength of the vehicle body is ensured. In vehicles where existing reinforcement R is installed, the ceiling molding material 1 may be placed in each region between the reinforcement R.

[0028] <Manufacturing process for vehicle molding materials> Next, the manufacturing process of the ceiling molding material 1 described above will be explained. The manufacturing process of the vehicle molding material according to this embodiment includes a bonding layer molding process, a lamination process, and a press molding process. As shown in Figure 2, the ceiling molding material 1 consists of a base material layer 2, a surface backing material 3 for bonding the ceiling molding material 1 to the ceiling panel P, and a nonwoven fabric sheet 12 laminated on the ceiling interior material side of the base material layer 2.

[0029] The bonding layer formation process involves laminating a bonding layer 9 onto the intermediate layer 8 of the planar backing material 3. Specifically, a flat laminate, formed by laminating a thermoplastic bonding film layer 15 and a nonwoven fabric layer 16, is passed through a roll coater 20, and an acrylic adhesive is applied to the surface of the nonwoven fabric layer 16 (see Figure 3). This forms the bonding layer 9 of the planar backing material 3. A release liner 10 is laminated onto the surface of the bonding layer 9, forming the planar backing material 3. For the release liner 10, a sheet material that does not melt from the heat of the heat press, such as paper or film, is selected.

[0030] In the lamination process, a planar backing material 3 is laminated onto the base material layer 2 (see Figure 4). The base material layer 2 consists of a core material 5 made of urethane resin, on which first and second fiber reinforcement layers 6 and 7, made of glass fiber mats coated with thermosetting adhesive 13, are laminated on both sides. The first fiber reinforcement layer 6 is placed on the ceiling panel P side of the core material 5, and the second fiber reinforcement layer 7 is placed on the ceiling interior side of the core material 5. A nonwoven fabric sheet 12 is laminated on the ceiling interior material side of the base material layer 2 to prevent the glass fibers from being exposed from the second fiber reinforcement layer 7. Through the lamination process, the intermediate layer 8 of the planar backing material 3 faces the first fiber reinforcement layer 6 in the base material layer 2.

[0031] In the press molding process, the base material layer 2, the planar backing material 3, and the nonwoven fabric sheet 12, which were laminated in the lamination process, are heated and pressurized by a press die 19 (see Figure 5). The thermosetting adhesive 13 melts due to the heat, joining the core material 5 and the fiber reinforcement layers 6 and 7 on both sides. In addition, the thermoplastic bonding film layer 15 melts due to the heat, joining the first fiber reinforcement layer 6 and the planar backing material 3. In this way, the base material layer 2 and the planar backing material 3 are joined together and formed into a three-dimensional planar shape that conforms to the surface of the ceiling panel P (see Figure 6).

[0032] Through the above process, a three-dimensional ceiling molding material 1 with a bonding layer 9 is obtained. The ceiling molding material 1 is bonded to the surface of the ceiling panel P. At this time, the release layer 10 is peeled off, and the ceiling molding material 1 and the ceiling panel P are surface-bonded by the bonding layer 9 (see Figure 7).

[0033] <Effects of the Embodiment> In the manufacturing process of the ceiling molding material 1 (vehicle molding material) according to the above embodiment, a surface backing material 3 having a bonding layer 9 is laminated onto a base material layer 2 in which a core material 5 and fiber reinforcement layers 6 and 7 are laminated via a thermosetting adhesive 13 (thermosetting resin), and then heated and pressure molded in a press die 19. Furthermore, a release layer 10 is laminated onto the bonding layer 9 of the surface backing material 3. Therefore, the bonding layer 9 does not come into contact with the press die during press molding, and the base material layer 2 and the surface backing material 3 can be molded as a single unit. Through these processes, a three-dimensional surface molding material 1 for vehicles with a bonding layer 9 evenly distributed across its surface can be molded without any post-processing after press molding.

[0034] According to the bonding layer formation process of the above embodiment, the bonding layer 9 is formed on the flat, planar backing material 3 before it is laminated onto the base material layer 2. By forming the bonding layer 9 on the planar backing material 3 in advance in a process prior to forming the ceiling molding material 1, it is possible to easily obtain a ceiling molding material 1 equipped with the bonding layer 9 compared to the case where the bonding layer 9 is laminated onto a three-dimensional molded body.

[0035] In the manufacturing process of the ceiling molded material 1 according to the above embodiment, a thermoplastic bonding film layer 15 and a nonwoven fabric layer 16 constituting the planar backing material 3 are laminated, and the laminate (intermediate layer 8) is passed through a roll coater 20 to apply adhesive and form a bonding layer 9. When applying adhesive processing to a three-dimensional molded body, a problem arises in that it cannot pass through the gaps of the roll coater 20, but in this respect, if the laminate is flat, adhesive processing with the roll coater 20 is easy.

[0036] The planar backing material 3 has a nonwoven fabric layer 16 on which a bonding layer 9 that can be bonded to the ceiling panel P is laminated, and a release layer 10 is laminated on the ceiling panel P side of the bonding layer 9. As a result, the planar backing material 3 and the base material layer 2 can be press-molded as a single unit without the bonding layer 9 coming into contact with the press die 19. In other words, by using a planar backing material 3 with these configurations, a three-dimensional planar ceiling molding material 1 can be formed with the bonding layer 9 evenly distributed across its surface.

[0037] The planar backing material 3 has a structure in which a bonding layer 9 is laminated on an intermediate layer 8, and the planar backing material 3 and the base material layer 2 are bonded by the bonding film layer 15 of the intermediate layer 8. For example, it is difficult to directly apply an adhesive as a bonding layer 9 to a glass fiber mat with a coarse basis, but by using the intermediate layer 8 as an intermediary, it becomes easier to laminate the adhesive (bonding layer 9) onto the glass fiber mat (first fiber reinforcement layer 6).

[0038] The planar backing material and the method for manufacturing a vehicle molded material equipped with the planar backing material according to the present invention are not limited to the appearance and configuration described in the above embodiments, and can be implemented in various other forms by various modifications, additions, deletions, and combinations of configurations without altering the essence of the present invention.

[0039] In this embodiment, an example of a ceiling molding material 1 disposed between the ceiling panel P and the ceiling interior material has been shown as a vehicle molding material, but it is not limited to this and can also be applied as a vehicle molding material in other parts of the vehicle.

[0040] The manufacturing process for a vehicle molding material according to the present invention does not necessarily include a step of manufacturing a planar backing material that includes the formation of a bonding layer. In other words, a vehicle molding material may be manufactured using a laminate that has been completed as a planar backing material with a bonding layer. [Explanation of symbols]

[0041] 1. Molded material for ceilings (molded material for vehicles) 2 Base material layer 3-sided backing material 5 Core material 6. First fiber reinforcement layer 7. Second fiber reinforcement layer 8. Middle layer 9 Bonding layer 10. Exfoliation layer 12 Nonwoven fabric sheets 13 Thermosetting adhesives (thermosetting resins) 15 Bonding film layer 16 Non-woven layer 19 Press mold P Ceiling panel (body panel) R reinforcement

Claims

1. A method for manufacturing a molding material for vehicles, The aforementioned vehicle molding material is A base layer comprising a core material and a fiber-reinforced layer laminated to the core material via a thermosetting resin, The vehicle body panel has a surface backing material facing the base material layer between the base material layer and the vehicle body panel, The aforementioned surface backing material is An intermediate layer comprising a thermoplastic bonding film layer and a nonwoven fabric layer laminated on the vehicle body panel side of the bonding film layer, The bonding layer laminated on the vehicle body panel side of the nonwoven fabric layer, The bonding layer comprises a release layer which is a sheet material laminated on the vehicle body panel side and is peelable from the bonding layer, The bonding layer is formed by a bonding layer formation step of laminating the bonding layer onto the nonwoven fabric layer, and a release layer is laminated onto the bonding layer, and the result is a flat plate shape. A lamination step of laminating the flat surface backing material onto the base material layer, A method for manufacturing a molded material for a vehicle, comprising a press molding step of joining the laminated base material layers and the planar backing material together by heating and pressurizing them in a press mold, and forming them into a planar shape that conforms to the surface of the vehicle body panel.

2. A method for manufacturing a vehicle molding material according to claim 1, The method for manufacturing a molded material for vehicles, wherein the bonding layer formation step involves applying an adhesive to the nonwoven fabric layer using a roll coater, thereby laminating the bonding layer.

3. A surface backing material in a vehicle molding material disposed between a vehicle body panel and vehicle interior material, An intermediate layer having a thermoplastic bonding film layer laminated on the vehicle body panel side of a base material layer comprising a core material and a fiber reinforcement layer laminated on the core material via a thermosetting resin, and a nonwoven fabric layer laminated on the vehicle body panel side of the bonding film layer, A bonding layer is laminated on the vehicle body panel side of the nonwoven fabric layer, and is capable of bonding the surface of the vehicle body panel to the vehicle molding material, A planar backing material having a release layer which is a sheet material laminated on the vehicle body panel side of the bonding layer and which can be peeled off from the bonding layer.

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