Lining material for molded ceiling for vehicle and molded ceiling for vehicle
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Solution Overview
Problem
Conventional molded ceiling materials for vehicles suffer from issues such as scaling and cracking due to differences in elongation between the heat-shielding layer and the base film, leading to deteriorated heat-shielding performance, especially in areas with significant undulations and shape changes during molding.
Innovation Solution
A lining material comprising a fiber layer, a heat-shielding film layer, and a barrier layer is used, where the fiber layer is a nonwoven fabric with high tensile strength and lower elasticity, integrated with the heat-shielding film layer to prevent excessive elongation, and the barrier layer inhibits airflow, thereby preventing scaling and cracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a resin film base material is used for the lining material, then the material can be easily molded and formed, but the base film stretches excessively during molding causing difference in elongation between the heat shielding layer and base film
Solution Approach 1:
The patent changes the physical parameters of the base material from a resin film to a nonwoven fabric, which has different mechanical properties including lower elasticity and controlled elongation characteristics, thereby resolving the elongation mismatch problem while maintaining moldability
Solution Approach 2:
The patent creates a composite structure by integrating the heat shielding layer with a nonwoven fabric base material, combining the heat reflection properties of metal particles with the dimensional stability of the nonwoven fabric to achieve both heat shielding performance and elongation control
2Reliability
If the heat shielding layer is formed by vapor-depositing aluminum on the base film, then the heat shielding function is achieved, but the heat shielding layer develops scaling and cracking in areas with significant undulation and shape changes
Solution Approach 1:
The patent changes the base material parameters to have lower elasticity and controlled elongation, which prevents excessive stretching of the heat shielding layer during molding, thereby preventing scaling and cracking while maintaining heat shielding performance
Solution Approach 2:
The nonwoven fabric acts as an intermediary material between the heat shielding layer and the molded ceiling structure, providing a stable substrate that accommodates shape changes without transmitting excessive stress to the heat shielding layer
3Adaptability or versatility
If a resin film with high elasticity is used, then the material can accommodate shape changes during molding, but the difference in elongation between the film and heat shielding layer causes excessive pressure and defects
Solution Approach 1:
The patent changes the elasticity parameter of the base material by using nonwoven fabric instead of resin film, achieving a balance between shape adaptability and elongation control, preventing both excessive stretching and molding defects
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The configuration ensures a stable heat-shielding effect by preventing differences in elongation between the fiber and heat-shielding layers, maintaining the integrity of the heat-shielding film, and improving heat reflection efficiency while reducing energy consumption by minimizing temperature rise in the vehicle cabin.
Implementation Method 1
The heat-shielding film layer consists of a metal film integrally formed with one side of the fiber layer to reflect radiant heat from the vehicle body panel side
Data Source
AI summary
A lining material for a molded ceiling for a vehicle is interposed between a base material of the molded ceiling and a vehicle body panel. The lining material has a fiber layer and a heat-shielding film layer. The fiber layer is a nonwoven fabric in the form of a sheet facing the vehicle body panel side. The heat-shielding film layer is a metal film integrated on one side of the fiber layer and reflects radiant heat from the vehicle body panel side. A barrier layer is laminated on the base material side of the fiber layer via adhesive resin. The barrier layer interrupts or inhibits airflow from the base material side.