阅读说明：本技术 车辆用成形车顶材及其制造方法 (Shaped roof material for vehicle and method for manufacturing same ) 是由 三上正彦 于 2020-01-29 设计创作，主要内容包括：一种车顶材本体(1a)包括：由硬质聚氨酯泡沫构成的基材层(2)、设置在基材层(2)的车厢内侧的第一纤维增强层(3)、设置在基材层(2)的车厢外侧的第二纤维增强层(4)、设置在第一纤维增强层(3)的车厢内侧的表皮层(5)、以及设置在第二纤维增强层(4)的车厢外侧的背面层(6)。第二纤维增强层(4)由重叠在基材层(2)上的玻璃纸(7)、以及重叠在玻璃纸(7)的基材层2相反侧的玻璃毡(8)构成。(A roof material body (1a) includes: the composite material comprises a base material layer (2) composed of hard polyurethane foam, a first fiber reinforced layer (3) arranged on the inner side of a carriage of the base material layer (2), a second fiber reinforced layer (4) arranged on the outer side of the carriage of the base material layer (2), a skin layer (5) arranged on the inner side of the carriage of the first fiber reinforced layer (3), and a back layer (6) arranged on the outer side of the carriage of the second fiber reinforced layer (4). The second fiber-reinforced layer (4) is composed of a glass paper (7) superimposed on the base material layer (2), and a glass mat (8) superimposed on the glass paper (7) on the opposite side of the base material layer (2).)

1. A shaped roof material for a vehicle, which has a plate-shaped roof material body disposed on the inner side of a vehicle compartment of a roof panel, is characterized in that,

the roof panel body includes:

a base material layer made of rigid polyurethane foam;

a first fiber-reinforced layer formed by curing the applied first binder, the first fiber-reinforced layer being provided on the vehicle interior side of the base material layer;

a second fiber-reinforced layer formed by curing the coated second adhesive and provided on the top sheet side of the base material layer;

a skin layer joined to the cabin inner side of the first fiber-reinforced layer using the first adhesive; and

a back layer bonded to the top sheet side of the second fiber-reinforced layer using the second adhesive;

the first fiber-reinforced layer is composed of a first felt material obtained by integrating a large number of chopped strands formed of glass filaments or basalt filaments, which are randomly stacked in a felt shape, with a binder,

the second fiber-reinforced layer is composed of a paper material made of glass filaments or basalt filaments and superimposed on the substrate layer, and a second felt material obtained by integrating a large number of chopped strands formed of glass filaments or basalt filaments and randomly stacked in a felt shape with a binder and superimposed on the paper material on the side opposite to the substrate layer.

2. The shaped roof panel for a vehicle according to claim 1,

the weight per unit area of the paper is set to 30 to 50g/m²，

The weight per unit area of the second felt material is set to 60-80g/m²。

3. A method for manufacturing a shaped roof material for a vehicle according to claim 1 or 2, wherein the shaped roof material for a vehicle is a thermoplastic resin,

the second fiber-reinforced layer is obtained by mixing a polyester fiber into a glass fiber or a basalt fiber and manufacturing the paper using an acetate-based treating agent, bundling the glass fiber or the basalt fiber treated with the silane-based treating agent into a fiber bundle, generating a large number of chopped strands from the fiber bundle and randomly spreading the chopped strands on the paper to pile them into a mat shape, and then integrating each chopped strand with the paper using a polyester binder to make the second mat material superposed on the paper.

4. A method for manufacturing a shaped roof material for a vehicle according to any one of claims 1 to 3,

the second adhesive is coated from the paper side of the second fibrous reinforcement layer.

Technical Field

The present invention relates to a vehicle shaped roof material (shaping material) disposed inside a vehicle interior of a roof panel in a vehicle.

Background

Conventionally, as a molded roof material for a vehicle, for example, a roof material is known in which a base material layer is made of rigid polyurethane foam or the like, fiber-reinforced layers are provided on both sides of the base material layer, and a skin layer and a back layer are provided on the outer sides of the respective fiber-reinforced layers. Each fiber-reinforced layer not only provides the necessary strength and rigidity to the molded roof material but also serves to maintain the shape of the molded roof material after molding, and a glass mat (glass mat) is generally used as the material. The glass mat can be obtained by: about 80 glass filaments having a diameter of about 10 to 15 μm were bundled into a fiber bundle having a width of 0.8 to 1.5mm, the fiber bundle was cut into a length of about 50mm to form a large number of chopped strands (chopped strand), and the large number of chopped strands were randomly scattered, stacked in a felt shape and bonded integrally with an adhesive. Since the fiber-reinforced layer formed of the glass mat has a large number of heavy parts in some parts when forming the roof material for a vehicle, the weight per unit area of the glass mat to be used is required to be set. The reason why the thick and heavy portion is locally present is that the glass filaments cannot be stretched or deformed, and therefore, when the shaped roof panel is formed, the glass filaments (chopped strands) adjacent to each other on the glass mat are displaced from each other along with the deformed portion, and therefore, for example, in a region where the shape significantly changes when the shaped roof panel is formed, the glass mat becomes thick and heavy. For the above reasons, a shaped roof material generally cannot be used having a weight per unit area of 100g/m in a nominal value²The following glass mats.

However, in recent years, in the automobile industry, improvement of strength and rigidity of parts for modularizing vehicle parts for labor saving and efficiency improvement and weight reduction of parts for improving fuel efficiency and performance are both required, and a lightweight structure capable of ensuring required strength and rigidity is required even for a molded roof material.

To solve this problem, for example, increasing the thickness of each fiber-reinforced layer is considered to improve the strength and rigidity of the shaped roof material.

However, as usualA structure for forming a roof panel of a vehicle, comprising: the thickness of the substrate layer made of rigid polyurethane foam was 8mm, and the basis weight of each fiber-reinforced layer made of glass mat was 100g/m²The amount of the binder applied to each fiber-reinforced layer was 15g/m²The skin layer of the nonwoven fabric was 200g/m²And a back layer comprising a film and a nonwoven fabric of 70.5g/m²Etc., in this case, however, the proportion of the weight of each fiber-reinforced layer and binder relative to the total weight of the shaped roof panel is about 31% by weight. Therefore, the shaped roof material has a feature that the ratio of the weight of each fiber-reinforced layer and the binder to the total weight of the shaped roof material is large, and therefore, although the strength and rigidity of the shaped roof material can be improved by increasing the thickness of each fiber-reinforced layer, there is a problem that the increase in the thickness of each fiber-reinforced layer greatly increases the weight of the entire shaped roof material.

In order to avoid this, it is considered to use a glass fiber paper which is thinner and more rigid than the glass mat and has a small variation in weight per unit area for each fiber-reinforced layer of the molded roof material.

The cellophane can be usually produced by a wet papermaking method using glass filaments, and for example, the molded roof covering for a vehicle of patent document 1 is obtained by press molding a laminate sheet, and fiber-reinforced layers made of cellophane are provided on both sides of a base layer made of rigid polyurethane foam, and a skin layer and a back layer are provided on the outer sides of the respective fiber-reinforced layers. The glass fiber used for the cellophane in patent document 1 has a size of about 25mm, which is longer than a conventional size of about 12mm, in order to prevent the occurrence of a state in which adjacent glass fibers are completely separated and perforated when they are shifted from each other during the forming process. Further, since the adhesion between the isocyanate-based adhesive and the cellophane is weak, by applying the isocyanate-based adhesive to the cellophane made of a silane-based treating agent having good compatibility with the isocyanate-based adhesive and press-molding the coated cellophane, the substrate layer, the fiber-reinforced layers, the skin layer, and the back layer can be bonded more firmly to each other with the isocyanate-based adhesive.

Further, a vehicle roof molding of patent document 2 includes: the present invention relates to a fiber reinforced plastic composite material for a vehicle, and more particularly, to a fiber reinforced plastic composite material for a vehicle, which comprises a base material layer made of rigid polyurethane foam, a first fiber reinforced layer made of a glass mat and provided on the vehicle interior side of the base material layer, a second fiber reinforced layer made of a glass paper and provided on the vehicle exterior side of the base material layer, a skin layer provided on the vehicle interior side of the first fiber reinforced layer, and a back layer provided on the vehicle exterior side of the second fiber reinforced layer. On the other hand, the film layer is sandwiched between the second fiber-reinforced layer and the back surface layer, and the film layer compensates for the shape retention of the molded roof material that is easily deformed by setting the density of the base material layer low. Further, as in patent document 1, cellophane made using a silane-based treating agent having good compatibility with an isocyanate-based adhesive is applied to the second fiber-reinforced layer, and the layers are firmly bonded to each other by the isocyanate-based adhesive.

Documents of the prior art

Patent document

Patent document 1: international publication No. 2010/029861

Patent document 2: japanese patent laid-open publication No. 2012 and 162138

Disclosure of Invention

Problems to be solved by the invention

However, in recent years, due to, for example, diversification of vehicle design, a region in which the shape is significantly changed may be provided in the molded roof material. Therefore, researchers have investigated whether structures such as those of patent documents 1 and 2 can be applied to these regions. In these molded roof materials, it has been found that the fiber-reinforced layer made of cellophane may be broken or wrinkled in a region where the shape is largely changed, and thus the intended result may not be obtained.

Therefore, researchers have further made extensive studies to achieve both improvement in strength and rigidity and reduction in weight of the molded roof material. The relationship between the deformation of the base material layer and the deformation of the fiber-reinforced layer was analyzed in detail, and one of the analyses was usedThe test specimens were subjected to a bulge forming test (dome forming test). In the experiment, samples T1, T2, and T3 were prepared as follows. Sample T1: the substrate layer has a density of 0.030g/m³The fiber reinforced layers on both sides of the substrate layer are 100g/m of unit area weight²The glass mat of (3), having the same structure as a conventional shaped roof; sample T2: the substrate layer has a density of 0.030g/m³The fiber reinforced layers on both sides of the substrate layer are 50g/m of unit area weight²The cellophane of (1) has the same structure as the molded roof material described in patent document 1; sample T3: the base material layer has a density of 0.022-0.024g/m³And a hard polyurethane foam having a basis weight of 100g/m provided on the vehicle interior side of the base material layer²And a fiber-reinforced layer formed of a glass mat of (2) and having a weight per unit area of 50g/m laminated on the outside of the vehicle compartment of the base material layer²The formed roof material obtained from the fiber-reinforced layer formed of cellophane according to (1) has the same structure as the formed roof material described in patent document 2. Then, a nearly conical die with a rounded tip was pushed from the skin layer side into each of samples T1 to T3 to deform each of samples T1 to T3, and the relationship between the elongation of each portion of samples T1 to T3 and the elongation of the base material layer was investigated according to the degree of change in the pattern generated on the surfaces of the base material layer and the fiber-reinforced layer.

Fig. 7 is a graph showing changes before and after deformation of the patterns generated on the surfaces of the base material layer and the fiber-reinforced layer in a predetermined cross section C passing through the portion corresponding to the vertex a of the die in each of the samples T1 to T3 after the bump forming, and calculating the elongation of the base material layer, in which the horizontal axis represents each portion of each of the samples T1 to T3, the vertical axis represents the elongation ratio of the base material layer, and the data D1 to D3 are data obtained by performing the bump forming on each of the samples T1 to T3. On the other hand, fig. 8 is a graph in which the fiber density at each part of the fiber-reinforced layer is calculated by observing the state of the fiber-reinforced layer on the section C, the horizontal axis represents each part of each sample T1-T3, and the vertical axis represents the fiber density, and the data d1-d3 are data obtained by subjecting each sample T1-T3 to bump forming.

As can be seen from the data D1, the substrate layer of sample T1 was largely deformed only in the region corresponding to the vertex a of the die, and the other regions retained the original shape with almost no deformation. On the other hand, as can be seen from the data d1, the fiber density of the fiber-reinforced layer of sample T1 is reduced in the region corresponding to the apex A of the die. This is considered because, in the case of the glass mat, the glass filaments (chopped strands) adjacent to each other are likely to be displaced from each other, and therefore, the glass filaments are similarly deformed as the portions of the base layer are deformed. That is, the fiber density of the region of the fiber-reinforced layer of sample T1 corresponding to the apex a of the die decreased because the chopped strands in the region of the fiber-reinforced layer corresponding to the region were greatly displaced from each other along with the region of the base layer in which large deformation occurred.

Next, it can be seen from the data D2 that the base material layer of the sample T2 was largely deformed in the region corresponding to the vertex a of the die, but the degree of deformation in this region was smaller than that of the sample T1, whereas the degree of deformation in the surrounding region was larger than that of the same region of the sample T1. On the other hand, as can be seen from the data d2, the fiber-reinforced layer of sample T2 has a fiber density not less than that of the same region of sample T1 in the region corresponding to the apex a of the die, but has a fiber density less than that of the same region of sample T1 in the surrounding region thereof. This is considered because, in the case of the cellophane, since the adjacent glass filaments are less likely to shift than the glass mat, the cellophane exerts a larger resistance to the base material layer when the base material layer is stretched, and thus the stretched regions of the base material layer are not concentrated in the region corresponding to the vertex a of the die but are dispersed around the region. However, it is found that in sample T2, the cellophane on the vehicle interior side broke in the region corresponding to the apex a of the die, and the cellophane on the vehicle interior side wrinkled in the region corresponding to the apex a of the die, and it was difficult to produce the molded roof material 1 in accordance with the structure of sample T2.

Finally, as can be seen from the data D3, the base material layer of specimen T3 was not deformed to the same extent as specimen T2 in the region corresponding to the apex a of the die, whereas the surrounding region was deformed to the same extent as specimen T2. On the other hand, as can be seen from the data d3, the fiber-reinforced layer of sample T3 has a fiber density not less than that of the same region of sample T2 in the region corresponding to the apex a of the die, but has a fiber density less than that of the same region of sample T2 in the surrounding region thereof. This is considered because, by making the fiber reinforced layer on the vehicle interior side from a glass mat and reducing the density of the base material layer so as to be more easily deformed than the sample T2, the base material layer itself can be flexibly deformed along the die even if a larger resistance than the cellophane is applied to the base material layer at the time of molding. In the case of sample T3, since the fiber-reinforced layer did not break in the region corresponding to the apex a of the die and further no wrinkles occurred in the glass mat on the vehicle interior side, even though it is highly likely that the product could be produced by the structure of sample T3, the film layer needs to be provided in view of the shape retention property, which causes problems of cost increase and weight increase.

That is, it is found that by applying a paper material such as cellophane to the forming roof material, it is possible to achieve both improvement in strength and rigidity and reduction in weight of the forming roof material. However, on the other hand, since the glass fibers constituting the glass paper are more densely entangled than the glass mat, if the fiber reinforced layers on both sides of the base material layer are made of glass paper, as shown in patent document 1, when the molded roof panel is formed, the resistance between the adjacent glass fibers in the glass paper increases, the amount of displacement between the glass fibers becomes insufficient, and the glass fibers cannot follow the change in shape, and particularly, the fiber reinforced layers on the vehicle outer side often break, and on the other hand, it is necessary to solve the problem that the fiber reinforced layers on the vehicle inner side are likely to wrinkle.

In addition, in the structure shown in patent document 2, although the fiber-reinforced layer on the vehicle outer side formed of the cellophane is less likely to break at the time of molding and the fiber-reinforced layer on the vehicle interior side formed of the glass mat is less likely to wrinkle, it is necessary to solve the problem that the increase in cost and weight is caused by the increase in the film layer to be added in order to maintain the shape of the molded roof panel.

The present invention has been made in view of the above points, and an object thereof is to provide a vehicle molded roof panel which can improve strength and rigidity without increasing weight, and which is excellent in moldability and low in cost.

Solutions for solving problems

In order to achieve the above object, the present invention is characterized in that a paper material and a felt material formed of glass filaments or basalt filaments are used when forming a formed roof material, and a manner of overlapping the paper material and the felt material on a base material layer is designed.

Specifically, the following solution is adopted for a molded roof material for a vehicle having a plate-shaped roof material body disposed inside a vehicle compartment of a roof panel (roof panel).

That is, in the invention of the first aspect, the roof material body includes: a base material layer made of rigid polyurethane foam; a first fiber-reinforced layer formed by curing the applied first binder, the first fiber-reinforced layer being provided on the vehicle interior side of the base material layer; a second fiber-reinforced layer formed by curing the coated second adhesive and provided on the top sheet side of the base material layer; a skin layer joined to the cabin inner side of the first fiber-reinforced layer using the first adhesive; and a back surface layer bonded to the top plate side of the second fiber-reinforced layer using the second adhesive. The first fiber-reinforced layer is composed of a first felt material obtained by integrating a large number of chopped strands formed of glass filaments or basalt filaments, which are randomly stacked in a felt shape, with a binder. The second fiber-reinforced layer is composed of a paper material made of glass filaments or basalt filaments and superimposed on the substrate layer, and a second felt material obtained by integrating a large number of chopped strands formed of glass filaments or basalt filaments and randomly stacked in a felt shape with a binder and superimposed on the paper material on the side opposite to the substrate layer.

A second aspect of the present invention is the paper of the first aspect, wherein the weight per unit area of the paper is set to 30 to 50g/m²The weight per unit area of the second felt material is set to 60-80g/m²。

A third aspect of the present invention is the first or second aspect of the present invention, wherein the second fiber-reinforced layer is obtained by mixing polyester fibers into glass filaments or basalt filaments and producing the paper material using an acetate-based treating agent, bundling the glass filaments or basalt filaments treated with the silane-based treating agent into a fiber bundle, generating a large number of chopped strands from the fiber bundle and randomly spreading the chopped strands on the paper material to pile them in a mat shape, and then integrating the chopped strands with the paper material using a polyester binder to form the second mat material superposed on the paper material.

The invention of the fourth aspect is the invention of any one of the first to third aspects, characterized in that the second adhesive is coated from the paper side of the second fiber-reinforced layer.

Effects of the invention

In the invention of the first aspect, when the base material layer is about to extend during the formation of the formed roof material, the paper material that is difficult to extend adjacent to the base material layer exerts a large resistance against the base material layer, and therefore the extending regions of the base material layer become dispersed without being concentrated. Therefore, since the large stretch in the narrow prescribed region in the second fiber-reinforced layer is reduced, the formability is improved and the frequency of occurrence of cracks in the second fiber-reinforced layer can be reduced. In addition, since the paper material is provided in part of the second fiber-reinforced layer, the strength and rigidity of the formed roof material can be improved without greatly changing the weight per unit area, as compared with a conventional structure in which the second fiber-reinforced layer is formed only of a second felt material such as a glass felt. In particular, since the paper material is disposed adjacent to the base material layer, the bonding area between the binder and the base material layer is increased as compared with the case where the second felt material is disposed adjacent to the base material layer, and thus the strength and rigidity of the molded roof panel can be improved and the shape retention property can be improved. Further, as in patent document 2, it is not necessary to provide a thin film layer to improve moldability and shape retention by reducing the density of the base material layer, and therefore, an increase in cost can be suppressed.

In the invention according to the second aspect, the ratio of the second felt material that is more deformable than the paper material is set to be large, and therefore, the formability can be further improved while the strength and rigidity of the forming roof material are not affected as much as possible.

In the invention of the third aspect, when the fiber-reinforced layer is manufactured, since the second felt is integrated with the paper material at the same time as the second felt is manufactured, it is not necessary to perform an operation of separately manufacturing the paper material and the second felt and then bonding the paper material and the second felt together with an adhesive, and therefore, the manufacturing cost and the component cost can be reduced.

In the invention of the fourth aspect, since the binder is sufficiently entangled in the paper material which is in direct contact with the substrate layer made of rigid polyurethane foam having a rough surface, the bonding area between the substrate layer and the second fiber-reinforced layer can be increased, and the substrate layer and the second fiber-reinforced layer can be firmly bonded together.

Drawings

Fig. 1 is a perspective view of a vehicle provided with a vehicle molded roof material according to an embodiment of the present invention.

Fig. 2 is a plan view of a vehicle shaped roof material according to an embodiment of the present invention.

Fig. 3 is a sectional view taken along line III-III of fig. 1.

Fig. 4 is a graph showing the results of a bulge forming test performed on a sample corresponding to a molded vehicle roof material according to an embodiment of the present invention, and shows the state of the fiber density of each part of the fiber-reinforced layer after molding.

Fig. 5 is a table showing the results of a study of the strength and rigidity at the central surface portion of the vehicle shaped roof material according to the embodiment of the present invention as compared with the conventional vehicle shaped roof material.

Fig. 6 is a table showing the results of the study of the strength and rigidity of the side surface portion of the vehicle shaped roof material according to the embodiment of the present invention as compared with the conventional vehicle shaped roof material.

Fig. 7 is a table showing the results of a study of the weight of the vehicle molded roof material according to the embodiment of the present invention as compared with a conventional vehicle molded roof material.

Fig. 8 is a photograph of a vehicle front side portion of the vehicle molded roof panel according to the embodiment of the present invention taken from the vehicle compartment inner side.

Fig. 9 is a photograph taken from the inside of the vehicle compartment by peeling the outside of the vehicle compartment from the base material layer at the vehicle front side portion of the molded roof material for a vehicle according to the embodiment of the present invention.

Fig. 10 is a graph showing the results of a bump forming test performed on a sample corresponding to a conventional vehicle molded roof panel, and shows the ratio of the elongation of each portion of the base material layer before and after molding.

Fig. 11 is a graph showing the results of a bulge forming test performed on a sample corresponding to a conventional vehicle molded roof panel, and shows the state of the fiber density of each part of the fiber-reinforced layer after molding.

Detailed Description

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. The following description of the preferred embodiments is merely exemplary in nature.

Fig. 1 shows a vehicle 10 including a vehicle molded roof panel 1 according to an embodiment of the present invention. The vehicle molding roof material 1 is disposed on the vehicle interior side of a roof panel 10a of a vehicle 10, and includes a plate-shaped roof material body 1a as shown in fig. 2.

The roof material body 1a is constituted by a central surface portion 1b and a pair of side surface portions 1c, the central surface portion 1b being obtained by press-molding a laminate sheet using a molding die (not shown) and extending substantially flat in the vehicle front-rear direction; the side surface portion 1c is provided continuously with each side edge portion of the central surface portion 1b, and is inclined gradually downward toward the vehicle width direction outer side.

As shown in fig. 3, the roof material body 1a includes: a base material layer 2 made of rigid polyurethane foam, a first fiber reinforced layer 3 provided on the vehicle interior side of the base material layer 2, a second fiber reinforced layer 4 provided on the roof panel 10a side of the base material layer 2, a skin layer 5 made of nonwoven fabric provided on the vehicle interior side of the first fiber reinforced layer 3, and a back layer 6 made of film and nonwoven fabric provided on the roof panel 10a side of the second fiber reinforced layer 4.

The density of the rigid polyurethane foam of the substrate layer 2 was 0.030g/m³And the thickness was set to 8 mm.

The first fiber-reinforced layer 3 is formed of a glass mat (first mat material) such thatA plurality of chopped strands formed of glass filaments and randomly stacked in a mat shape were integrated with a binder, and the weight per unit area was 100g/m². The first fibrous reinforcement layer 3 is made by passing at 15g/m²The first adhesive 3a made of isocyanate-based resin applied is cured to form the adhesive, and the first adhesive 3a is impregnated into the base material layer 2 and cured to be bonded to the base material layer 2.

The second fiber-reinforced layer 4 is composed of a glassine paper 7 (paper material) and a glass mat 8 (second mat material), the glassine paper 7 being made of glass filaments, and the glass mat 8 being obtained by integrating a large number of chopped strands formed of glass filaments and randomly stacked in a mat shape with a binder. The cellophane 7 is superposed on the base material layer 2, and the glass mat 8 is superposed on the cellophane 7 on the opposite side of the base material layer 2.

The second fibrous reinforcement layer 4 is obtained by the following method: mixing 4.5 wt% of polyester fiber into glass fiber with fiber length of 12-13mm, and making into glass fiber with unit area weight of 30g/m by using acetate ester treating agent²The glass fiber sheets 7 were then bundled into fiber bundles, a large number of chopped strands were produced from the fiber bundles, the chopped strands were randomly scattered on the glass fiber sheets 7 and stacked in a mat shape, and then the chopped strands and the glass fiber sheets 7 were integrated with each other using a polyester binder so that the weight per unit area of the glass fiber sheets 7 superimposed thereon was 70g/m²The glass mat 8.

Further, the second fiber-reinforced layer 4 was formed by passing the fiber at 15g/m²The second adhesive 4a made of the isocyanate-based resin applied is cured, and the second fiber-reinforced layer 4 is bonded to the base layer 2 by impregnating and curing the base layer 2 with the second adhesive 4 a. Note that the second adhesive 4a is applied from the cellophane 7 side of the second fiber-reinforced layer 4.

The weight per unit area of the skin layer 5 was 200g/m²The first fiber-reinforced layer 3 is joined by the first adhesive 3a penetrating from the first fiber-reinforced layer 3 into the skin layer 5.

On the other hand, the weight per unit area of the back surface layer 6 was 70.5g/m²By a second bond penetrating from the second fibrous reinforcement layer 4 into the back layer 6The agent 4a is joined to the second fiber-reinforced layer 4.

Here, in order to analyze the relationship between the deformation of the base material layer 2 and the deformation of the second fiber-reinforced layer 4 in the vehicle shaped roof material 1 according to the embodiment of the present invention, a bump forming test similar to the above-described test samples T1-T3 was performed in a manner similar to the test sample T4 prepared from the shaped roof material 1.

Fig. 4 is a graph in which the state of the second fiber-reinforced layer 4 is observed on a predetermined cross section C of a portion corresponding to the apex a of the die of the sample T4 after the protrusion formation, and the fiber density of each of the portions of the cellophane 7 and the glass mat 8 of the second fiber-reinforced layer 4 is measured, the horizontal axis represents each portion of the sample T4, the vertical axis represents the fiber density, the data d4 represents the state of the cellophane 7, and the data d5 represents the state of the glass mat 8.

It can be seen from the data d5 that the fiber density of the region of the glass mat 8 of the sample T4 corresponding to the apex a of the die is not lower than that in the case where the fiber-reinforced layer on the cabin outer side is constituted by only the glass mat as in the sample T1.

On the other hand, as can be seen from the data d4, although the fiber density of the region corresponding to the apex a of the die of the cellophane 7 of the sample T4 is not lower than that in the case where the fiber-reinforced layer is constituted only by the glass mat as in the sample T1, the fiber density of the region corresponding to the apex a of the die is decreased if compared with the glass mat 8 of the sample T4. That is, it is found that the second fiber-reinforced layer 4 has better formability during forming than the case of being composed of only a glass mat.

In order to confirm whether or not the moldability was improved even when the weights per unit areas of the cellophane 7 and the glass mat 8 were slightly changed, the weight per unit area of the cellophane 7 in the sample T4 was changed to 30g/m²-50g/m²And the weight per unit area of the glass mat 8 was changed to 60g/m²-80g/m²The same bump forming test was carried out to confirm that the weight per unit area of the cellophane 7 obtained in the sample T4 was 30g/m²And the weight per unit area of the glass mat 8 was 70g/m²The same result was obtained.

As a result, the vehicle molded roof panel 1 according to the embodiment of the present invention has good moldability even when it is heavy as in the conventional molded roof panels, and can reduce the possibility that the second fiber-reinforced layer 4 is broken during molding and becomes a defective product.

Next, the evaluation results of the strength and rigidity of the vehicle shaped roof panel 1 according to the embodiment of the present invention will be described.

In fig. 5 to 7, in order to examine whether or not the strength and rigidity of the vehicle shaped roof material 1 according to the embodiment of the present invention are improved as compared with the conventional shaped roof material, the conventional shaped roof material (test material a), the material obtained by increasing the weight per unit area and the amount of the adhesive agent of the fiber reinforced layer on the vehicle compartment outer side of the conventional shaped roof material (test material B), and the vehicle shaped roof material 1 according to the embodiment of the present invention (test material C to test material G) were used as the test materials, and the maximum bending load, the bending elastic gradient, and the rear surface side peel strength were examined in two directions, respectively. In the conventional molded roof material, for example, in order to improve the workability in assembling the vehicle, a glass mat layer may be added only between the base material layer on the side surface portion (see fig. 2) and the fiber reinforced layer on the vehicle compartment outer side. That is, in order to increase the rigidity of the shaped roof material, the rigidity of only necessary portions of the shaped roof material, not the rigidity of the entire shaped roof material, may be increased to prevent an increase in the total weight of the shaped roof material, and therefore such a material is prepared as the test material a'.

The test material a was: substrate layer (Density: 0.030 g/m)³And thickness: 8mm), two fiber-reinforced layers (material: glass mat, unit area weight: 100g/m²) Binder (coating amount: 15g/m²) Skin layer (weight per unit area: 200g/m²) And a back surface layer (material: film and nonwoven, basis weight: 70.5g/m²). As the test material a', a weight per unit area was added between the base material layer and the fiber-reinforced layer on the vehicle compartment outer side: 135g/m²A glass mat layer of (2).

Test material B was: substrate layer (Density: 0.030 g/m)³And thickness: 8mm), surface side fiber reinforced layer(Material: glass mat, basis weight: 100 g/m)²) And a backside fiber-reinforced layer (material: glass mat, unit area weight: 230g/m²) Surface side adhesive (coating amount: 15g/m²) And a back-side adhesive (coating amount: 20g/m²) Skin layer (weight per unit area: 200g/m²) And a back surface layer (material: film and nonwoven, basis weight: 70.5g/m²)。

Test material C was: substrate layer 2 (Density: 0.030 g/m)³And thickness: 8mm), the first fiber-reinforced layer 3 (material: glass mat, unit area weight: 100g/m²) And a second fiber-reinforced layer 4 (material: laminate of cellophane 7 and glass mat 8, basis weight of cellophane 7: 30g/m²Unit area weight of the glass mat 8: 70g/m²) First binder 3a (coating amount: 15g/m²) And a second binder 4a (coating amount: 20g/m²) Skin layer 5 (weight per unit area: 200g/m²) And a back surface layer 6 (material: film and nonwoven, basis weight: 70.5g/m²)。

Test material D was: substrate layer 2 (Density: 0.030 g/m)³And thickness: 8mm), the first fiber-reinforced layer 3 (material: glass mat, unit area weight: 100g/m²) And a second fiber-reinforced layer 4 (material: laminate of cellophane 7 and glass mat 8, basis weight of cellophane 7: 30g/m²Unit area weight of the glass mat 8: 60g/m²) First binder 3a (coating amount: 15g/m²) And a second binder 4a (coating amount: 20g/m²) Skin layer 5 (weight per unit area: 200g/m²) And a back surface layer 6 (material: film and nonwoven, basis weight: 70.5g/m²)。

Test material E was: substrate layer 2 (Density: 0.030 g/m)³And thickness: 8mm), the first fiber-reinforced layer 3 (material: glass mat, unit area weight: 100g/m²) And a second fiber-reinforced layer 4 (material: laminate of cellophane 7 and glass mat 8, basis weight of cellophane 7: 40g/m²Unit area weight of the glass mat 8: 70g/m²) First binder 3a (coating amount: 15g/m²) And a second binder 4a (coating amount: 20g/m²) Skin layer 5 (weight per unit area: 200g/m²) And a back surface layer 6 (material: film and nonwoven, basis weight: 70.5g/m²)。

Test material F was: substrate layer 2 (Density: 0.030 g/m)³And thickness: 8mm), the first fiber-reinforced layer 3 (material: glass mat, unit area weight: 100g/m²) And a second fiber-reinforced layer 4 (material: laminate of cellophane 7 and glass mat 8, basis weight of cellophane 7: 40g/m²Unit area weight of the glass mat 8: 80g/m²) First binder 3a (coating amount: 15g/m²) And a second binder 4a (coating amount: 20g/m²) Skin layer 5 (weight per unit area: 200g/m²) And a back surface layer 6 (material: film and nonwoven, basis weight: 70.5g/m²)。

Test material G was: substrate layer 2 (Density: 0.030 g/m)³And thickness: 8mm), the first fiber-reinforced layer 3 (material: glass mat, unit area weight: 100g/m²) And a second fiber-reinforced layer 4 (material: laminate of cellophane 7 and glass mat 8, basis weight of cellophane 7: 50g/m²Unit area weight of the glass mat 8: 80g/m²) First binder 3a (coating amount: 15g/m²) And a second binder 4a (coating amount: 20g/m²) Skin layer 5 (weight per unit area: 200g/m²) And a back surface layer 6 (material: film and nonwoven, basis weight: 70.5g/m²)。

For each of the test materials A, A', B-G, 12 sheets were measured and the average value was calculated. In addition, the peel strength on the back side was measured between the base material layer and the fiber-reinforced layer on the vehicle cabin outer side, and between the fiber-reinforced layer on the vehicle cabin outer side and the back layer. Further, for the test material C, the position of the cellophane 7 of the second fiber-reinforced layer 4 was also determined to be opposite to the position of the glass mat 8. In addition to this, for the test material C, two materials in which the second binder 4a was applied from the cellophane 7 side of the second fiber-reinforced layer 4 and the second binder 4a was applied from the glass mat 8 side of the second fiber-reinforced layer 4 were measured. The data of fig. 6 were measured using a test material having a thickness of 5.5mm, which was the same as that of the conventional molded roof material, for the side surface part 1 b.

From the test results, it is understood that the strength and rigidity of the test materials C to G in which the cellophane 7 of the second fiber-reinforced layer 4 is disposed on the substrate layer 2 side and the second adhesive 4a is applied from the cellophane 7 side are increased by about 1.5 to 2 times at the same weight as that of the test material a which is the conventional molded roof material, and that the test materials C to G are also lighter and have improved strength and rigidity over the entire area of the roof material body 1a, as compared with the test material a' in which a glass mat layer is added only between the substrate layer on the side surface portion and the fiber-reinforced layer on the vehicle cabin outer side and the test material B in which the amounts of the fiber-reinforced layer on the vehicle cabin outer side and the adhesive on the vehicle cabin outer side are increased.

On the other hand, even in the test material C, if the glass mat 8 of the second fiber-reinforced layer 4 is disposed on the side of the base material layer 2, the strength and rigidity are not improved to the desired extent. This is considered because the mesh size of the glass mat 8 is larger than that of the cellophane 7, and the bonding area with the base material layer 2 (the area in contact with the base material layer 2) is narrower than that of the cellophane 7. From this, it is understood that by disposing the cellophane 7 adjacent to the base material layer 2, the bonding area of the second binder 4a to the base material layer 2 is increased as compared with disposing the glass mat 8 adjacent to the base material layer 2, and thus the strength and rigidity of the molded roof panel 1 can be improved and the shape retainability can be improved.

Further, from the result of test C, it is also found that even when the cellophane 7 of the second fiber-reinforced layer 4 is disposed on the substrate layer 2 side, sufficient strength and rigidity cannot be obtained without applying the second binder 4a from the cellophane 7 side of the second fiber-reinforced layer 4. This is considered because the surface of the base material layer 2 made of rigid polyurethane foam is rough, and therefore if the cellophane 7 directly contacting the base material layer 2 does not sufficiently entangle the second adhesive 4a, the bonding area with the base material layer 2 becomes narrow and the adhesive force is lowered.

Fig. 8 is a photograph of the vehicle molded roof panel 1 according to the embodiment of the present invention taken from the inside of the vehicle compartment in the area X1 where the shape change is the largest during molding, and it is understood that no unevenness is generated in the area X1. In addition, no wrinkles were formed in the entire surface layer 5, and a molded roof panel 1 having a high commercial value was formed.

Fig. 9 is a photograph taken from the inside of the vehicle cabin after the area outside the vehicle cabin is peeled from the base material layer 2 of the molded roof panel 1 for a vehicle, and the X2 portion is a position corresponding to the X1 portion in fig. 8. The cellophane 7 of the X2 portion was not broken, and the glass mat 8 of the X2 portion became thick and heavy in weight per unit area, but was in a state sufficient to maintain strength and rigidity.

Thus, if the second fiber-reinforced layer 4 is configured to sequentially overlap the cellophane 7 and the glass mat 8 from the substrate layer 2 side as in the molded roof panel 1 for a vehicle according to the embodiment of the present invention, when the substrate layer 2 is about to be stretched during the molding of the molded roof panel 1, the cellophane 7 adjacent to the substrate layer 2, which is difficult to stretch, exerts a large resistance on the substrate layer 2, and the stretching regions of the substrate layer 2 are dispersed and not concentrated. Therefore, since the large stretch in the narrow prescribed region in the second fiber-reinforced layer 4 is reduced, the formability is improved and the frequency of occurrence of cracks in the second fiber-reinforced layer 4 can be reduced.

In addition, since the cellophane 7 is provided in a part of the second fiber-reinforced layer 4, the strength and rigidity of the shaped roof panel 1 can be improved without greatly changing the weight per unit area, as compared with the conventional structure in which the second fiber-reinforced layer 4 is formed of only the glass mat 8.

Further, according to the embodiment of the present invention, it is not necessary to reduce the density of the base material layer 2 or provide a thin film layer in order to improve moldability and shape retention as in patent document 2, and therefore an increase in cost can be suppressed.

In addition, in the second fiber-reinforced layer 4, the weight per unit area of the cellophane 7 was set to 30g/m²And the weight per unit area of the glass mat 8 was set to 70g/m²Since the proportion of the glass mat 8 that is more easily deformed than the cellophane 7 is set to be large, the formability can be further improved while the strength and rigidity of the forming roof material 1 are not affected as much as possible.

In addition, in the case of manufacturing the second fiber-reinforced layer 4, since the glass mat 8 and the glass paper 7 are integrated at the same time as the glass mat 8 is manufactured, it is not necessary to perform an operation of separately manufacturing the glass paper 7 and the glass mat 8 and then bonding the glass paper 7 and the glass mat 8 with an adhesive, and therefore, the manufacturing cost and the component cost can be reduced.

In addition, since the second adhesive 4a is applied from the cellophane 7 side of the second fiber reinforced layer 4, the second adhesive 4a is sufficiently entangled in the cellophane 7 in direct contact with the base material layer 2 made of rigid polyurethane foam having a rough surface. Therefore, the bonding area between the base material layer 2 and the second fiber-reinforced layer 4 can be increased, so that the base material layer 2 and the second fiber-reinforced layer 4 can be firmly joined together.

In the embodiment of the present invention, the first fiber-reinforced layer 3 is made of a glass mat, and the second fiber-reinforced layer 4 is made of a glass paper 7 and a glass mat 8 made of glass filaments, but even if these paper and each mat are made of basalt filaments obtained from basalt, a formed roof material 1 having the same material properties as those made of glass filaments can be obtained. Since the glass filaments are locally crystallized and become industrial waste when burned, and the basalt filaments are ash when burned and can return to the nature directly, if the paper material and the second felt material of the first and second fiber-reinforced layers 3 and 4 are made of basalt filaments, the molded roof material 1 can be made into an environmentally friendly product.

In addition, in the embodiment of the present invention, the glass mat 8 and the glass paper 7 are integrally overlapped in the process of manufacturing the glass mat 8, but it is also possible to separately manufacture the glass paper 7 and the glass mat 8 and then to manufacture the second fiber-reinforced layer 4 by laminating the glass paper 7 and the glass mat 8 by using, for example, EVA (ethylene-ethyl acetate copolymer resin).

In the embodiment of the present invention, the treatment agent is an acetate-based treatment agent or a silane-based treatment agent when the glassine paper 7 and the glass mat 8 are produced, but the glassine paper 7 and the glass mat 8 may be produced using other treatment agents as long as the compatibility between the glassine paper 7 and the glass mat 8 and the isocyanate-based second binder 4a can be improved.

Industrial availability-

The present invention is suitable for a vehicle shaped roof material provided on the inner side of a vehicle compartment of a vehicle roof panel.

-description of symbols-

1: shaped roof material for vehicle

1 a: car roof material body

2: substrate layer

3: first fiber-reinforced layer

3 a: first adhesive

4: second fiber-reinforced layer

4 a: second adhesive

5: epidermal layer

6: back layer

7: glassine paper (paper material)

8: glass mat (second felt material)