JP2018039339A - Molded ceiling material for vehicles - Google Patents

Abstract

[Problem] To provide a molded ceiling material for vehicles that can reduce the weight of the entire vehicle while improving soundproofing inside the vehicle cabin. [Solution] A soundproofing and heat-insulating mat 3 is attached to the exterior surface of the ceiling material body 2, and the soundproofing and heat-insulating mat 3 has a plurality of independent flexible cells 4 arranged in parallel along the exterior surface of the ceiling material body 2. The interior of each cell 4 is filled with a large amount of urethane foam material 6. [Selected Figure] Figure 2

Description

  The present invention relates to a molded ceiling material for a vehicle provided on a vehicle interior side of a roof panel in a vehicle.

  In recent years, in vehicles such as automobiles, many efforts have been made to improve soundproofing (sound absorption, sound insulation) and heat insulation in the passenger compartment. For example, a molded ceiling material for a vehicle disclosed in Patent Document 1 includes a panel-like ceiling material body facing a vehicle interior, and a foam molded body made of urethane foam is disposed outside the vehicle interior of the ceiling material body. Is integrally formed so as to be substantially equal to the shape of the roof panel on the vehicle interior side. The exterior of the foam molded body is pressed against the roof panel interior, and the space between the ceiling material body and the roof panel is filled with the foam molded body to improve soundproofing and heat insulation. .

JP 2011-225150 A

  However, if the space between the ceiling material body and the roof panel is filled with a foamed molded body made of urethane foam as in Patent Document 1, the weight of the entire vehicle is greatly increased, although the soundproofing and heat insulating properties in the passenger compartment increase. The demand for reducing the weight of the entire vehicle for the purpose of improving the fuel efficiency of the vehicle in recent years cannot be satisfied.

  The present invention has been made in view of such a point, and an object of the present invention is to provide a molded ceiling material for a vehicle that can reduce the weight of the entire vehicle while improving soundproofing and heat insulation in a vehicle interior. There is to do.

  In order to achieve the above object, the present invention is characterized in that a soundproof and heat insulating mat comprising a plurality of cells is provided on the roof panel side of the ceiling material body.

  Specifically, the following solution has been taken for a molded ceiling material for a vehicle that is provided on the vehicle interior side of the roof panel of the vehicle and has a panel-like ceiling material body facing the vehicle interior.

  That is, in the first invention, a cell assembly having a plurality of independent flexible cells arranged side by side along a surface of the ceiling material main body outside the vehicle cabin on the outside of the ceiling material main body. Each cell is filled with at least one of a large number of flexible bodies and gases.

  According to a second aspect, in the first aspect, the outside of the cell assembly of the cell assembly is set so as to be in contact with the surface of the roof panel on the inside of the vehicle interior.

  According to a third invention, in the first invention, an aluminum sheet is integrally provided on at least one of the roof panel side of the cell assembly and the ceiling material body side of the cell assembly. And

  According to a fourth invention, in the third invention, the aluminum sheet is provided on the roof panel side, and a large number of through holes are formed over the entire area.

  According to a fifth invention, in any one of the first to fourth inventions, the inside of each cell is filled with nitrogen.

  According to a sixth invention, in any one of the first to fourth inventions, the inside of each of the cells is filled with a large number of foamed urethane materials.

  In the first aspect of the invention, the cell assembly has an uneven surface on the roof panel side due to the surface of each cell in the form of a bag, so that the sound that enters the vehicle interior via the roof panel is the surface of each cell. Attenuated by irregular reflection. Therefore, it is difficult for the sound that enters the vehicle interior via the roof panel to move to the vehicle interior via the ceiling material body, so that the soundproofing performance can be improved. In addition, since the cell assembly fills a large area in the space between the ceiling material body and the roof panel, convection between the ceiling material body and the roof panel is prevented, and the heat insulation in the vehicle interior is improved. be able to. Further, the molded ceiling for a vehicle as described in the cited reference 1 in which the space between the ceiling material body and the roof panel is filled up by the amount of space formed between the roof panel and the cell assembly by the uneven surface of the cell assembly. The weight of the entire molded ceiling material for a vehicle can be reduced compared to the material.

  In the second invention, since the cell assembly comes into contact with both the ceiling material body and the roof panel, the vibration damping property for suppressing the vibration of the ceiling material body and the roof panel is enhanced, and the soundproofing of the molded ceiling material for the vehicle is achieved. The performance can be further increased.

  In the third aspect of the invention, since the reflectance of the vehicle molded ceiling material is increased without increasing the weight of the entire vehicle molded ceiling material as much as possible, the vehicle molded ceiling material can be made light in weight and having a high heat shielding effect.

  In the fourth aspect of the invention, the sound entering the vehicle interior via the roof panel is attenuated by the resistance when passing through each through hole of the aluminum sheet, and the soundproof performance can be further enhanced.

  In the fifth invention, since the coefficient of thermal expansion in each cell is low, the size of each cell is difficult to change even if the temperature of the outside air and the passenger compartment varies. Therefore, it can be avoided that each cell expands and bursts, or that each cell contracts and the sound absorbing performance is deteriorated.

  In the sixth invention, since the urethane foam material has high sound insulation performance as well as heat insulation performance, the foam urethane material filled in each cell enhances not only the sound absorption performance of the vehicle molded ceiling material but also the heat insulation performance. Can do. In addition, even if one of the cells ruptures, the shape of the cell is maintained by the foamed urethane material filled in the cell. Can be prevented from decreasing.

It is the perspective view which simplified the vehicle which concerns on Embodiment 1 of this invention. It is the top view which looked at the ceiling material main body of the molded ceiling material for vehicles which concerns on Embodiment 1 of this invention from the vehicle interior outer side. It is sectional drawing in the III-III line of FIG. It is the graph which evaluated the soundproof performance about the molded ceiling material for vehicles which concerns on Embodiment 1 of this invention. FIG. 3 is a view corresponding to FIG. 2 according to Embodiment 2 of the present invention. It is a cross-sectional equivalent view in the VI-VI line in FIG. FIG. 7 is a view corresponding to FIG. 6 according to Embodiment 3 of the present invention. FIG. 6 is a view corresponding to FIG. 6 according to Embodiment 4 of the present invention. FIG. 7 is a view corresponding to FIG. 6 according to Embodiment 5 of the present invention.

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

Embodiment 1 of the Invention
FIG. 1 shows a vehicle 10 according to Embodiment 1 of the present invention. As shown in FIG. 3, the roof panel 10a of the vehicle 10 includes a roof panel outer 10b having a substantially rectangular shape in a plan view as an outer plate portion of the vehicle 10, and a vehicle width along the lower surface of the roof panel outer 10b. A roof reinforcement 10c having a hat-shaped cross section extending in the direction, and five roof reinforcements 10c are provided at predetermined intervals in the vehicle front-rear direction.

  On the vehicle interior side of the roof panel 10a, a molded ceiling material 1 for a vehicle is disposed so as to cover the entire area of the roof panel 10a.

  As shown in FIGS. 2 and 3, the molded ceiling material 1 for a vehicle includes a substantially rectangular panel-shaped ceiling material body 2 facing the vehicle interior side, and a soundproofing attached to the vehicle exterior side of the ceiling material body 2. And a heat insulating mat 3 (cell assembly).

  Although the ceiling material body 2 is not shown in the figure, for example, it has a structure in which a surface layer and a back layer are laminated via a reinforcing layer such as glass fiber on a urethane layer made of rigid foamed urethane, and a molding die not shown is used. And formed by a conventionally known method.

  As shown in FIG. 2, an overhead console opening 2a having a rectangular shape in plan view is formed in the center portion of the ceiling material body 2 on the front side of the vehicle.

  In addition, a lamp unit opening 2b having a rectangular shape in a plan view is formed at the center of the ceiling material body 2 in the vehicle front-rear direction.

  The soundproof and heat insulating mat 3 has a cylindrical shape extending in the vehicle width direction and a plurality of flexible cells 4 arranged in parallel in the vehicle front-rear direction, and a nonwoven fabric sheet 5 covering the roof panel 10a side of all the cells 4. The nonwoven fabric sheet 5 is set so as to be in contact with the vehicle interior side surface (the roof panel outer 10b and the roof reinforcements 10c) of the roof panel 10a.

  Each of the cells 4 is made of a vinyl chloride material and is independent of each other. Each chip 4 is filled with a large number of chip-like urethane foam materials 6 (flexible bodies).

  In FIG. 3, each cell 4 and the nonwoven fabric sheet 5 are exaggerated for convenience.

  Here, the evaluation result about the soundproof performance of the molded ceiling material 1 for vehicles which concerns on embodiment of this invention is demonstrated.

  FIG. 4 is a graph in which the horizontal axis represents frequency and the vertical axis represents sound transmission loss. The higher the sound transmission loss at each frequency, the higher the soundproofing performance. D1 shows the data acquired in the state where there is no soundproofing and heat insulating mat 3 between the roof panel 10a and the ceiling material body 2, and D2 is the soundproofing heat insulating mat 3 of the present invention and the nonwoven fabric sheet 5 is on the roof panel 10a side. D3 shows the data acquired by setting between the roof panel 10a and the ceiling material body 2 as described above, and D3 is the roof panel 10a so that the nonwoven fabric sheet 5 is on the ceiling material body 2 side. D4 shows the data acquired by setting between the ceiling material body 2 and the ceiling material body 2, and each cell 4 in the soundproof and heat insulating mat 3 of the present invention is formed of a nonwoven fabric, and the soundproof and heat insulating mat 3 is formed of the nonwoven fabric sheet 5 on the roof panel 10a. The data acquired by setting between the roof panel 10a and the ceiling material main body 2 so as to be on the side are shown.

  As shown in FIG. 4, when the molded ceiling material 1 for a vehicle according to the first embodiment of the present invention is provided between the ceiling material body 2 and the roof panel 10a, the nonwoven fabric sheet 5 is positioned on the roof panel 10a side, or Regardless of whether it is located on the ceiling material body 2 side, higher soundproofing performance can be obtained than in the case where there is no soundproofing and heat insulating mat 3 between the ceiling material body 2 and the roof panel 10a in all regions from low frequency to high frequency. I found out that

  Further, when the soundproof and heat insulating mat 3 in which each cell 4 is formed of a nonwoven fabric is provided between the ceiling material body 2 and the roof panel 10a, the soundproofing is provided between the ceiling material body 2 and the roof panel 10a in a region of 2.5 kHz or less. It was found that higher soundproofing performance can be obtained compared to the case without the heat insulating mat 3.

  As described above, according to the first embodiment of the present invention, the soundproof and heat insulating mat 3 has an uneven surface on the roof panel 10a side by the surface of each bag-shaped cell 4, and therefore, the vehicle interior is provided via the roof panel 10a. The sound that enters inside is attenuated by irregular reflection on the surface of each cell 4. Therefore, the sound that enters the vehicle interior via the ceiling material main body 2 becomes difficult to move to the vehicle interior via the ceiling material main body 2, so that the soundproof performance can be improved. Further, since the soundproof and heat insulating mat 3 fills a large area in the space between the ceiling material body 2 and the roof panel 10a, convection between the ceiling material body 2 and the roof panel 10a is prevented, and the vehicle interior It is possible to improve the heat insulation. Furthermore, the space between the ceiling material main body 2 and the roof panel 10a is filled up by the amount of space formed between the roof panel 10a and the soundproof and heat insulating mat 3 by the uneven surface of the soundproof and heat insulating mat 3. Compared to such a molded ceiling material 1 for a vehicle, the weight of the entire molded ceiling material 1 for a vehicle can be reduced by the amount of space formed between the roof panel 10a and the soundproof and heat insulating mat 3.

  Further, since the soundproof and heat insulating mat 3 is in contact with the interior side of the roof panel 10a, the soundproof and heat insulating mat 3 is in contact with both the ceiling material body 2 and the roof panel 10a. Therefore, the vibration control property which suppresses the vibration of the ceiling material main body 2 and the roof panel 10a is enhanced, and the soundproof performance of the molded ceiling material 1 for a vehicle can be further enhanced.

  Furthermore, since each cell 4 is filled with a large number of urethane foam materials 6 that have not only sound absorption performance but also high heat insulation performance, not only the sound absorption performance of the vehicle molded ceiling material 1 but also the heat insulation performance can be enhanced. . In addition, even if one of the cells 4 is ruptured, the shape of the cell 4 is maintained by the foamed urethane material 6 filled in the cell 4, so that the cell 4 may burst during use. It is possible to prevent the soundproof performance and the heat insulation performance from deteriorating rapidly.

  In Embodiment 1 of the present invention, each cell 4 is filled with a large number of urethane foam materials 6, but is not limited thereto, and may be filled with gas, for example, may be filled with nitrogen. . If it does so, since the coefficient of thermal expansion in each cell 4 will become low, the magnitude | size of each cell 4 becomes difficult to change with the fluctuation | variation of outside air and the temperature of a vehicle interior. Therefore, it can be avoided that each cell 4 expands and ruptures, or that each cell 4 contracts and the sound absorption performance decreases.

  Moreover, in Embodiment 1 of this invention, although the sound-insulation heat-insulating mat 3 is in contact with the vehicle interior side of the roof panel 10a, it is not essential to contact.

  Moreover, in Embodiment 1 of this invention, although the inside of each cell 4 is satisfy | filled with many foaming urethane materials 6, you may make it fill the inside of each cell 4 with another flexible body. For example, each cell 4 may be filled with a collection of cells smaller than each cell 4.

  In the embodiment of the present invention, the inside of each cell 4 is filled with a large number of foamed urethane materials 6, but not only the foamed urethane material 6 but also other flexible bodies are mixed, or the foamed urethane material 6 and A configuration in which nitrogen is mixed may be used.

  Moreover, in Embodiment 1 of this invention, although each cell 4 was formed with the vinyl chloride material, you may form with a nonwoven fabric, a polyethylene terephthalate, a recycled paper etc. not only this.

<< Embodiment 2 of the Invention >>
5 and 6 show a ceiling material body 2 according to Embodiment 2 of the present invention. In the second embodiment, only a part of the structure of the soundproofing and heat insulating mat 3 is different from that of the first embodiment, and the other parts are the same as those of the first embodiment. .

  The soundproof and heat insulating mat 3 according to Embodiment 2 includes a pair of cushion sheets 7 made of polyethylene terephthalate.

  The cushion sheet 7 includes a film sheet 7a extending in the vehicle front-rear direction and a large number of bag-like cells 7b formed over the entire area of one surface of the film sheet 7a. Is enclosed.

  And both the said cushion sheets 7 are overlaid so that each cell 7b side may face.

  An aluminum sheet 8 is integrally attached to the entire area of the other surface of each film sheet 7a using an adhesive, and the aluminum sheet 8 attached to one cushion sheet 7 is attached to the vehicle of the roof panel 10a. The aluminum sheet 8 attached to the other cushion sheet 7 is in contact with the surface of the ceiling material body 2 on the outside of the passenger compartment, while being in contact with the indoor side surfaces (the roof panel outer 10b and the roof reinforcements 10c). Yes.

  A large number of through holes 8a are formed in the aluminum sheet 8 on the roof panel 10a side, and each of the through holes 8a has a substantially circular cross section.

  As described above, according to the second embodiment of the present invention, the aluminum sheet 8 is interposed between the roof panel 10a and the soundproof and heat insulating mat 3, and between the ceiling material body 2 and the soundproof and heat insulating mat 3, so that The reflectance in the molded ceiling material 1 for a vehicle is increased without increasing the weight of the entire molded ceiling material 1 as much as possible. Therefore, the molded ceiling material 1 for a vehicle can be light and have a high heat shielding effect.

  In addition, since the aluminum sheet 8 on the roof panel 10a side has a large number of through holes 8a, sound entering the vehicle compartment through the roof panel 10a passes through the through holes 8a of the aluminum sheet 8. It becomes attenuated by the resistance at the time, and the soundproofing performance can be further enhanced.

  In addition, in Embodiment 2 of this invention, although the through-hole 8a is formed in the aluminum sheet 8 by the side of the roof panel 10a, forming the through-hole 8a in the aluminum sheet 8 is not essential.

  Moreover, in Embodiment 2 of this invention, although the cross section of each through-hole 8a formed in the aluminum sheet 8 by the side of the roof panel 10a has comprised substantially circular shape, it is not limited to this, For example, it has comprised slit shape. Also good.

  In Embodiment 2 of the present invention, the through hole 8a is formed in the aluminum sheet 8 on the roof panel 10a side. However, the through hole 8a may be formed in the aluminum sheet 8 on the ceiling material body 2 side.

<< Embodiment 3 of the Invention >>
FIG. 7 shows a ceiling material body 2 according to Embodiment 3 of the present invention. In the third embodiment, there is only one cushion sheet 7 in the soundproof and heat insulating mat 3, and the cushion sheet 7 is disposed so that the cell 7b side faces upward, and the aluminum sheet 8 on the roof panel 10a side The only difference from Embodiment 2 is that the through-hole 8a is not formed, and the rest is the same as Embodiment 2, and detailed description thereof will be omitted.

  As described above, according to Embodiment 3 of the present invention, the soundproof and heat insulating mat 3 can be made lighter and thinner than the soundproof and heat insulating mat 3 of Embodiment 2.

<< Embodiment 4 of the Invention >>
FIG. 8 shows a ceiling material body 2 according to Embodiment 4 of the present invention. In the fourth embodiment, the point that the two cushion sheets 7 are overlapped so that the cell 7b side faces upward, and the point that the through hole 8a is not formed in the aluminum sheet 8 on the roof panel 10a side are the same as in the second embodiment. Since only the difference is the same as the second embodiment, the detailed description is omitted below.

  As described above, according to the fourth embodiment of the present invention, the same effect as in the second embodiment can be obtained even when the two cushion sheets 7 are overlapped.

<< Embodiment 5 of the Invention >>
FIG. 9 shows a ceiling material body 2 according to Embodiment 5 of the present invention. In the fifth embodiment, the structure of the cushion sheet 7 located on the lower side of the two cushion sheets 7 and the point that the through hole 8a is not formed in the aluminum sheet 8 on the roof panel 10a side are the same as in the second embodiment. Since only the differences are the same as in the second embodiment, only the parts different from the second embodiment will be described in detail below.

  The cushion sheet 7 located on the lower side of the fifth embodiment has a shape in which a large number of cells 7b are arranged in parallel in the vehicle front-rear direction and the vehicle width direction. Specifically, the cushion sheet 7 located on the lower side of the fifth embodiment includes a pair of film sheets 7c arranged in parallel up and down, and a number of wall sheets 7d that bridge the film sheets 7c up and down. And a gas is enclosed in a portion surrounded by the two film sheets 7a and the wall sheet 7d.

  As described above, according to the fifth embodiment of the present invention, the same effects as those of the second embodiment can be obtained even if the structures of the two cushion sheets 7 in the soundproof and heat insulating mat 3 are different from each other.

  In Embodiments 2 to 5 of the present invention, gas is sealed inside each cell 7b. However, as in Embodiment 1, a large number of urethane foam materials 6 may be filled in each cell 7b. Good.

  Moreover, in Embodiment 2-5 of this invention, although each cell 7b was formed with the polyethylene terephthalate, you may form not only this but with a nonwoven fabric, a vinyl chloride material, a recycled paper.

  The present invention is suitable for a molded ceiling material for a vehicle provided on the vehicle interior side of a roof panel in a vehicle.

DESCRIPTION OF SYMBOLS 1 Molded ceiling material for vehicles 2 Ceiling material body 3 Soundproof and heat insulating mat (cell assembly)
4 cells 6 Urethane foam material (flexible body)
7b cell 8 aluminum sheet 8a through hole 10 vehicle 10a roof panel

Claims (6)

A molded ceiling material for a vehicle that is provided on the vehicle interior side of a vehicle roof panel and includes a panel-like ceiling material body facing the vehicle interior,
A cell assembly having a plurality of independent flexible cells arranged side by side along the surface of the ceiling material main body outside the vehicle cabin is provided on the outside of the ceiling material main body.
Each of the cells is filled with at least one of a large number of flexible bodies and gases. The molded ceiling member for a vehicle according to claim 1,
A molded ceiling material for a vehicle, wherein an outer side of the vehicle compartment of the cell assembly is set to contact a surface of the roof panel on the vehicle interior side. The molded ceiling member for a vehicle according to claim 1,
A molded ceiling material for a vehicle, wherein an aluminum sheet is integrally provided on at least one of the roof panel side of the cell assembly and the ceiling material body side of the cell assembly. The molded ceiling material for a vehicle according to claim 3,
A molded ceiling material for a vehicle, wherein the aluminum sheet is provided on the roof panel side, and a plurality of through holes are formed over the entire area. In the molded ceiling material for vehicles as described in any one of Claim 1 to 4,
A molded ceiling material for a vehicle, wherein each cell is filled with nitrogen. In the molded ceiling material for vehicles as described in any one of Claim 1 to 4,
A molded ceiling material for a vehicle, wherein each cell is filled with a large number of foamed urethane materials.

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