JP2018176979A - Skin material used for molded ceiling for vehicle - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a skin material capable of making a design surface smooth by suppressing a thermosetting adhesive from infiltrating into the inside of the skin material, and making irregularities smooth in accordance with an uneven shape which a molded ceiling for vehicle has.SOLUTION: A skin material 1 is used for a molded ceiling for vehicle. The skin material 1 comprises: a surface layer 11 formed as a design surface 11a facing an indoor side of a vehicle; a first flexible polyurethane foam 12 laminated on one surface 11b of the surface layer 11; and a second flexible polyurethane foam 13 laminated on an opposite surface 12b to a surface 12a on which the surface layer 11 of the first flexible polyurethane foam 12 is laminated. The compression residual strain of the first flexible polyurethane foam 12 is relatively smaller than the compression residual strain of the second flexible polyurethane foam 13.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a surface material used for a molded ceiling for a vehicle.

  A molded vehicle ceiling is generally manufactured by integrally molding a base material responsible for maintaining the shape of the molded vehicle ceiling and a skin material provided with a design surface facing the indoor side of the vehicle by heat pressing. Also, in order to bond the surface material and the base material, a fiber reinforcing material layer to which a thermosetting adhesive is applied is provided on the surface material side of the base material, and the thermosetting bonding is performed in the process of heat pressing. The agent adheres the skin material and the base material.

  Generally, in a molded ceiling for a vehicle, in order to give an aesthetic appearance to a designed surface facing the interior side of the vehicle, it is necessary to make the designed surface smooth. Here, if the thermosetting adhesive applied to the fiber reinforcing material layer of the base material penetrates deep inside the skin material in the process of hot pressing, the design provided for the skin material with the thermosetting adhesive that has penetrated Irregularities occur on the surface, and the smoothness of the design surface is easily impaired. Then, the skin material which can control that a thermosetting adhesive penetrates into the skin material inside is indicated (for example, patent documents 1).

  The skin material described in Patent Document 1 has a configuration in which a non-woven fabric layer, a soft polyurethane foam layer, and a surface layer configured as a design surface facing the indoor side of a vehicle are laminated from the base material side. The non-woven fabric layer prevents the thermosetting adhesive from penetrating from the substrate to the skin material. For this reason, since unevenness is not generated in the surface layer of the surface material by the thermosetting adhesive, it is possible to make the design surface of the surface layer smooth.

JP, 2014-31073, A

  However, the non-woven fabric has regularity and restrictions on expansion and contraction in the surface direction. For example, the improvement of the molding of the ceiling material has been achieved due to the fact that the difference in expansion and contraction in directions crossing each other in the plane direction is large and that expansion and contraction are limited. Also, in order to prevent the thermosetting adhesive from penetrating into the interior of the skin material, it is conceivable to increase the fabric weight of the non-woven fabric, but on the other hand there is a concern that the weight of the whole skin may increase. .

  The present invention has been made in view of the above-mentioned point, and the problem to be solved by the present invention is to suppress the penetration of the thermosetting adhesive into the interior of the skin material, and to form the vehicle An object of the present invention is to provide a skin material which can make a design surface smooth by smoothing the unevenness according to the unevenness shape of the ceiling.

  In order to solve the said subject, the surface material used for the molded ceiling for vehicles of this invention contains the following structures. First, a first invention is a skin material used for a molded ceiling for a vehicle, and a first soft layer laminated on a surface layer configured as a design surface facing the indoor side of the vehicle and one surface of the surface layer. It has a polyurethane foam and a second flexible polyurethane foam laminated on the side opposite to the side on which the surface layer of the first flexible polyurethane foam is laminated. The compressive residual strain of the first flexible polyurethane foam is in a relationship relatively smaller than the compressive residual strain of the second flexible polyurethane foam.

  Here, the compressive residual strain is a phenomenon generally called sag. The greater the compressive residual strain, the more likely it to sag. According to the first aspect of the invention, the compressive residual strain of the first flexible polyurethane foam is in a relatively smaller relationship than the compressive residual strain of the second flexible polyurethane foam. In other words, the compressive residual strain of the second flexible polyurethane foam is relatively larger than the compressive residual strain of the first flexible polyurethane foam. Therefore, the second flexible polyurethane foam can be compressed more than the first flexible polyurethane foam in the process of heat-pressing the skin material and the base material. Then, the second flexible polyurethane foam is compressed to increase its density, and is deformed in accordance with the uneven shape of the surface material and adheres to the surface material. For this reason, the second flexible polyurethane foam can suppress penetration of the thermosetting adhesive from the base material into the interior of the skin material. As a result, penetration of the thermosetting adhesive into the interior of the skin material can suppress the formation of irregularities on the design surface of the surface layer. In addition, since the flexible polyurethane foam can be flexibly expanded and contracted, the second flexible polyurethane foam can smooth the unevenness of the molded vehicle ceiling.

  Here, in order to form the concavo-convex shape of the molded ceiling for a vehicle, the skin material and the base material are deformed from a plate shape into a concavo-convex shape by being heated and pressed by a heat press. In the process of deforming the skin material into a shape having a concavo-convex shape, the stress is partially concentrated, and the skin material expands and contracts in accordance with the stress. Therefore, the second flexible polyurethane foam suppresses the penetration of the thermosetting adhesive into the interior of the skin material, and makes the asperities smooth according to the asperity shape of the molded vehicle ceiling. It is necessary to be able to deform flexibly not only in the thickness direction. And since the second flexible polyurethane foam is formed of the flexible polyurethane foam, it can be flexibly deformed not only in the surface direction but also in the thickness direction. Therefore, it is preferable for the surface material to have the second flexible polyurethane foam having no regularity or restriction in the expansion and contraction in the surface direction like the conventionally used non-woven fabric for forming a molded ceiling for a vehicle having an uneven shape. is there. As described above, the second flexible polyurethane foam suppresses penetration of the thermosetting adhesive into the interior of the skin material, and smoothes the irregularities according to the irregularities of the molded vehicle ceiling. , The design surface can be made smooth.

  On the other hand, the compressive residual strain of the first flexible polyurethane foam is relatively smaller than the compressive residual strain of the second flexible polyurethane foam. For this reason, in the process of heat-pressing the skin material and the base material, the first flexible polyurethane foam is less likely to be compressed than the second flexible polyurethane foam. As a result, distortion does not easily occur on the surface of the first flexible polyurethane foam. Therefore, since the surface layer laminated on the first flexible polyurethane foam may be less likely to be distorted, the design surface of the surface layer may be a smooth surface. As described above, since the first flexible polyurethane foam is difficult to be compressed, the design surface of the skin material can be made smooth. Then, as described above, the first flexible polyurethane foam and the second flexible polyurethane foam suppress penetration of the thermosetting adhesive into the interior of the skin material, and the uneven shape of the molded vehicle ceiling The design surface can be made smooth by smoothing the unevenness accordingly.

Next, according to a second invention, in the skin material used for the molded ceiling for a vehicle according to the first invention, the second flexible polyurethane foam has a compressive residual strain when compressed 50% under conditions of 70.degree. C. for 22 hours. 70% less 40% and a density preferably has a 27 kg / m ³ or more 34 kg / m ³ the following characteristics.

  Here, the compressive residual strain is a phenomenon generally called sag. The measurement method of compressive residual strain conforms to JIS K 6400-4 and ASTM D3574. That is, the measurement of compressive residual strain is carried out 50% compression of the second flexible polyurethane foam and maintained at 70 ° C. for 22 hours. Then release the compression at room temperature and measure the thickness after 30 minutes. The compressive residual strain is a rate of reduction of the thickness after 30 minutes with respect to the original thickness.

  According to the second invention, the second flexible polyurethane foam is more easily compressed in the process of heat-pressing the skin material and the substrate by the mold by having the above-mentioned characteristics, and further more Flexible and flexible. Since the second flexible polyurethane foam has a high density by being compressed, the second flexible polyurethane foam can further suppress penetration of the thermosetting adhesive from the substrate into the interior of the skin material. As a result, penetration of the thermosetting adhesive into the interior of the skin material can further suppress the occurrence of irregularities on the design surface of the surface layer. In addition, since the second flexible polyurethane foam can expand and contract more flexibly, the second flexible polyurethane foam can further smooth the unevenness of the molded vehicle ceiling. As described above, the second flexible polyurethane foam further suppresses penetration of the thermosetting adhesive into the interior, and makes the asperities even smoother in accordance with the asperity shape of the molded vehicle ceiling. Can make the design surface smoother.

Next, according to the third invention, in the skin material used for the molded ceiling for a vehicle of the first invention or the second invention, the first flexible polyurethane foam is compressed 50% under conditions of 70 ° C. and 22 hours. compressive residual strain of 15% or less of more than 5%, it is preferred that the density has a 25 Kg / m ³ or more 30 Kg / m ³ following characteristics.

  Here, as described above, the method of measuring the compressive residual strain conforms to JIS K 6400-4 and ASTM D3574. That is, measurement of compressive residual strain is performed by compressing the first flexible polyurethane foam by 50% and maintaining it at 70 ° C. for 22 hours. Then release the compression at room temperature and measure the thickness after 30 minutes. The compressive residual strain is a rate of reduction of the thickness after 30 minutes with respect to the original thickness. According to the third aspect of the present invention, the first flexible polyurethane foam having the above-mentioned characteristics further reduces compression residual strain, and therefore the first flexible polyurethane foam is more difficult to be compressed in the process of hot pressing the skin material and the base material. For this reason, the first flexible polyurethane foam has a cushioning property in the molded vehicle ceiling manufactured through the process of heat-pressing the skin material and the base material. Therefore, the first flexible polyurethane foam can impart a pleasant touch to the cushioning material and, in turn, can impart a pleasant touch to the design surface of the molded vehicle ceiling. Further, since the first flexible polyurethane foam is more difficult to be compressed, distortion is less likely to occur on the surface side surface. Therefore, since the surface layer laminated on the first flexible polyurethane foam is less likely to be distorted, the design surface of the surface layer may be a smoother surface. As described above, since the first flexible polyurethane foam is more difficult to be compressed, the design surface can be given a pleasant feeling due to cushioning, and the design surface of the surface material can be made smoother.

  According to the present invention, the configuration of each of the above-described inventions prevents penetration of the thermosetting adhesive into the interior of the skin material, and makes the asperities smooth according to the asperity shape of the molded vehicle ceiling. By doing this, it is possible to provide a surface material that can make the design surface smooth.

It is a longitudinal cross-sectional view of a skin material. It is the schematic of the frame lamination construction method which manufactures a skin material. It is a longitudinal cross-sectional view of a surface material and a base material. It is a schematic diagram of a mode that a skin material and a base material are integrally formed by heat press. 1 is a perspective view of a molded vehicle ceiling. It is a longitudinal cross-sectional view of the skin material laminated on a substrate before being heated and pressed by heat press. It is a longitudinal cross-sectional view of the surface material laminated | stacked on the base material, after being heated and pressurized by heat press.

  Hereinafter, an embodiment for carrying out the present invention will be described with reference to FIGS. The vehicle is equipped with a steel panel roof panel to be a roof. A molded vehicle ceiling 3 is mounted on the indoor side of the roof panel. Although the details will be described later, the molded vehicle ceiling 3 is formed by thermally pressing the surface material 1 having a design surface and the base material 2 having a function of maintaining the shape of the vehicle molded ceiling 3. is there. In addition, a thermosetting adhesive is applied to the base material 2, and the skin material 1 and the base material 2 are adhered by the thermosetting adhesive in the process of hot pressing.

<About skin material 1>
As shown in FIG. 1, the surface material 1 includes a surface layer 11, a first flexible polyurethane foam 12, and a second flexible polyurethane foam 13. In FIG. 1, the upper side of the skin material 1 is the indoor side of the vehicle. The upper surface of the surface layer 11 is a design surface 11a facing the interior side of the vehicle. The surface layer 11 is made of a fabric such as a fabric. The surface layer 11 can be variously applied to fabrics such as fabrics, cloths and knits, woven fabrics, non-woven fabrics, fabric members such as raised blankets, synthetic leather, artificial leather, genuine leather and the like.

The first flexible polyurethane foam 12 is laminated on the side 11 b (one side) opposite to the design surface 11 a of the surface layer 11. The first flexible polyurethane foam 12 was an ether-based polyurethane foam. The first flexible polyurethane foam 12, 70 ° C., compressive strain remaining when compressed 50% 15% 5% or more or less under the conditions of 22 hours, density 25 Kg / m ³ or more 30 Kg / m ³ or less of It has a characteristic. Moreover, the thickness of the 1st flexible polyurethane foam 12 shall be 0.5 mm or more and 2 mm or less. Here, the compressive residual strain is a phenomenon generally called sag. The measurement method of compressive residual strain conforms to JIS K 6400-4 and ASTM D3574. That is, measurement of compressive residual strain is performed by compressing the first flexible polyurethane foam by 50% and maintaining it at 70 ° C. for 22 hours. Then release the compression at room temperature and measure the thickness after 30 minutes. The compressive residual strain is a rate of reduction of the thickness after 30 minutes with respect to the original thickness.

If the compression residual strain of the first flexible polyurethane foam 12 is less than 5%, the cushioning property of the first flexible polyurethane foam 12 is low, which is not preferable. In addition, when the compressive residual strain of the first flexible polyurethane foam 12 is larger than 15%, the first flexible polyurethane foam 12 is compressed in the process of heat-pressing the surface material 1 and the base material 2 with a molding die to provide cushioning properties. Is not preferable because the Generally, the lower the density of the polyurethane foam, the more likely it to sag. However, if the density of the first flexible polyurethane foam 12 is less than 25 kg / m ³ , it is not preferable because it tends to sag. Moreover, when the density of the first flexible polyurethane foam 12 is more than 30 kg / m ³ , the weight is excessively increased, which is not preferable. Furthermore, if the thickness of the first flexible polyurethane foam 12 is thinner than 0.5 mm, it is not preferable because the thickness does not become constant due to the difficulty in the production method. If the thickness of the first flexible polyurethane foam 12 is not constant, the smoothness of the surface layer 11 may be reduced. Moreover, when the thickness of the first flexible polyurethane foam 12 is thicker than 2 mm, the weight is excessively increased, which is not preferable.

The second flexible polyurethane foam 13 is laminated on the surface 12 b side opposite to the surface 12 a on which the surface layer 11 of the first flexible polyurethane foam 12 is laminated. The second flexible polyurethane foam 13 was an ether-based polyurethane foam. The second flexible polyurethane foams 13, 70 ° C., compressive strain remaining when compressed 50% at 40% to 70% in 22 hours under a density of 27 kg / m ³ or more 34 kg / m ³ or less of the characteristic Have. Moreover, the thickness of the 2nd flexible polyurethane foam 13 shall be 1 mm or more and 2 mm or less. Here, as described above, the method of measuring the compressive residual strain conforms to JIS K 6400-4 and ASTM D3574. That is, the measurement of compressive residual strain is carried out 50% compression of the second flexible polyurethane foam 13 and maintained at 70 ° C. for 22 hours. Then release the compression at room temperature and measure the thickness after 30 minutes. The compressive residual strain is a rate of reduction of the thickness after 30 minutes with respect to the original thickness.

  In the process of heat-pressing the surface material 1 and the base material 2 described above with a mold, the second flexible polyurethane foam 13 is deformed according to the uneven shape of the vehicle molded ceiling 3 while being compressed. If the compression residual strain of the second flexible polyurethane foam 13 is less than 40%, the time required to compress the second flexible polyurethane foam 13 in the process of heat-pressing the skin material 1 and the base material 2 in a mold. It is not preferable because it takes too much. In addition, when the compression residual strain of the second flexible polyurethane foam 13 is greater than 70%, the second flexible polyurethane foam 13 is partially excessive when deformed in accordance with the unevenness of the substrate during the heat pressing process. It is not preferable because there is a risk of thinning and holes may be opened. In the second flexible polyurethane foam 13, if there are excessively thin portions or portions with holes, the thermosetting adhesive penetrates into the interior of the skin material from these portions, so the design surface of the surface layer 11 There is a possibility that unevenness may occur in 11a.

And if the density of the second flexible polyurethane foam 13 is less than 27 kg / m ³ , the compressed second flexible polyurethane foam 13 is excessive in the process of heat-pressing the skin material 1 and the base material 2 with the molding die. Unfavorably because it becomes thinner. If the second flexible polyurethane foam 13 is excessively thin, the thermosetting adhesive penetrates into the interior of the skin material, and as a result, the design surface 11a of the surface layer 11 has irregularities, and the design surface 11a is not smooth and Is not preferable. Further, if the density of the second flexible polyurethane foam 13 is larger than 34 kg / m ³ , the weight is excessively increased, which is not preferable. Furthermore, if the thickness of the second flexible polyurethane foam 13 is thinner than 1 mm, the second flexible polyurethane foam 13 compressed in the process of heat-pressing the surface material 1 and the base material 2 with a molding die becomes excessively thin. Absent. If the thickness of the second flexible polyurethane foam 13 is thicker than 2 mm, the weight of the skin material as a whole is excessively increased, which is not preferable. Furthermore, it is not preferable because it takes too much time to compress the second flexible polyurethane foam 13 during the heat pressing process.

<About the manufacture of the surface material 1>
The skin material 1 is manufactured by a frame laminating method. Here, as shown in FIG. 1, let the surfaces on the indoor side (upper surfaces in FIG. 1) of the surface layer 11, the first flexible polyurethane foam 12, and the second flexible polyurethane foam 13 be 11a, 12a, 13a. . In addition, surfaces opposite to these surfaces (in FIG. 1, lower surfaces are referred to as 11 b, 12 b, and 13 b, respectively).

  The process in which the skin material 1 is manufactured by the frame lamination method is shown by FIG. In FIG. 2, reference numeral 11 denotes a surface layer 11 wound in a roll shape. Reference numeral 12 denotes a first flexible polyurethane foam 12 wound into a roll. And 13 is the 2nd flexible polyurethane foam 13 wound by roll shape.

  In this frame laminating method, as shown in FIG. 2, the surface 12a of the first flexible polyurethane foam 12 is cast and melted by the flame of the gas burner 101, and the surface layer 11 is superposed there and passed between the rolls 103 and 104. By these processes, the first flexible polyurethane foam 12 and the surface layer 11 are welded. Subsequently, the surface 12b of the first flexible polyurethane foam 12 is covered and melted by the flame of the gas burner 102, and the second flexible polyurethane foam 13 is stacked, passed between the rolls 104 and 105, and wound up in a roll. The skin material 1 is manufactured by welding the 1st flexible polyurethane foam 12 and the 2nd flexible polyurethane foam 13 by these processes. Furthermore, the surface material 1 is wound into a roll. As described above, the skin material 1 is manufactured by the frame laminating method.

  In the above-described frame laminating method, the surface 12b of the first flexible polyurethane foam 12 is covered in the process of welding the first flexible polyurethane foam 12 and the second flexible polyurethane foam 13; It may be the surface 13 a of the foam 13. By gathering the surface 13 a of the second flexible polyurethane foam 13, the density of the surface 13 a of the second flexible polyurethane foam 13 is increased. Therefore, since the surface 13a of the second flexible polyurethane foam 13 has a high density, it is in a state in which the thermosetting adhesive hardly penetrates before hot pressing. Therefore, by rubbing the surface 13a of the second flexible polyurethane foam 13, penetration of the thermosetting adhesive into the interior of the skin material in the process of hot pressing can be further suppressed.

  Further, the characteristics of the first flexible polyurethane foam 12 and the second flexible polyurethane foam 13 described above, that is, the compressive residual strain, the density and the thickness are the characteristics of the polyurethane foam before being welded by the frame laminating method.

<About base material 2>
The cross section of the skin material 1 and the base material 2 is shown by FIG. Further, as described later, the molded ceiling 3 for a vehicle is formed by integrally forming a laminate of the skin material 1 and the base material 2 as shown in FIG. 3 by heat pressing. In FIG. 3, the upper side is the inside of the vehicle, as in FIG. 1.

  The base material 2 is a part responsible for shape retention of the molded vehicle ceiling 3, securing of rigidity, sound absorption in a vehicle interior, heat insulation and the like. Then, as shown in FIG. 3, the base material 2 has a fiber reinforcing material 21 impregnated with a thermosetting adhesive, a core material 22, a fiber reinforcing material 23 impregnated with a thermosetting adhesive, and no air flow. Film 24 and the backing material 25 are laminated. The substrate 2 is generally manufactured as follows. First, a thermosetting adhesive is applied to both sides of the core 22, and the fiber reinforcements 21 and 23 are laminated on both sides of the core 22. Next, the non-air-permeable film 24 and the backing material 25 are laminated on one side. Although the thermosetting adhesive is applied to both surfaces of the core material 22 in the above, a fiber reinforcing material in which the fiber reinforcing materials 21 and 23 are impregnated with the thermosetting adhesive in advance may be used instead. Furthermore, the core material 22 may be coated with a thermosetting adhesive, using a fiber reinforcement impregnated with a thermosetting adhesive in advance.

  The core material 22 selected the urethane foam of the semi-hard layer which consists of a urethane-resin foam body by this embodiment. The core material 22 can be variously applied such as fiber type, cardboard type, urethane type, foamed olefin type and the like. The core member 22 is provided for shape retention and rigidity, and may have a mode in which sound absorption inside the vehicle compartment and heat insulation are provided.

  The fiber reinforcements 21 and 23 are provided to maintain the shape and the rigidity of the entire vehicle molded ceiling 3. The fiber reinforcements 21 and 23 are glass fiber mats formed into a sheet shape by appropriately setting chopped strands obtained by cutting glass fibers which are inorganic fibers into appropriate lengths (for example, 50 mm to 100 mm) with a binder. In the embodiment, it is selected. The glass fiber used here is not only the chopped strands consolidated as described above, but also the ones consolidated with a binder without cutting the glass fibers (continuum as a mat) or glass fiber non-woven fabric, glass fiber paper, glass It may be a fiber woven fabric. The coating weight can be selected to meet the required strength and various other conditions. In addition, the fiber reinforcements 21 and 23 may be inorganic fibers such as chopped strands, organic fibers such as jute (juice), kenaf (loaf), ramie, hemp (hemp), sisal, natural fibers such as bamboo, etc. A sheet-like or mat-like one by a binder such as acrylic or needle processing may be appropriately selected.

  As the thermosetting adhesive, a thermosetting resin consisting of an isocyanate resin was selected in this embodiment. As described above, the core material 22 composed of the urethane foam of the semi-rigid layer and the second flexible polyurethane foam 13 consist of the urethane foam. From the viewpoint of compatibility with these urethane foams, it is preferable that an isocyanate resin is selected as the thermosetting adhesive. The thermosetting adhesive is not limited to the isocyanate resin and can be appropriately selected. The thermosetting resin is applied to the core 22 and the fiber reinforcements 21 and 23 by a spray, a roll coater, or the like. The application amount is an amount that meets the required strength and other various conditions.

  The backing material 25 was selected from polyethylene terephthalate (PET) resin fiber non-woven fabric. In addition, various synthetic fiber nonwoven fabrics, such as a polyamide type, polyester type, a polyacryl nitrile type, are applicable to the backing material 25.

<About the process of forming the molded ceiling 3 for vehicles from the surface material 1 and the base material 2>
FIG. 4 schematically shows how the surface material 1 and the base material 2 are integrally formed by heat pressing. As shown in FIG. 4, the skin material 1 is set together with the base material 2 between the molds 201 and 202 having a molding surface formed into a required curved surface, and the skin material 1 and the base material are performed by heat pressing. The two are integrally formed to obtain a molded ceiling 3 for a vehicle. Here, the skin material 1 and the base material 2 are laminated as shown in FIG. 3 and heat-pressed. The perspective view from the base material 2 side of the molded ceiling 3 for vehicles is shown by FIG. As shown in FIG. 5, the molded vehicle ceiling 3 has a required uneven shape like hills 3a to 3c. In the present embodiment, the molded ceiling 3 for a vehicle is a molded ceiling for a vehicle, but the skin material 1 can be used not only for a vehicle but also for a molded ceiling of a vehicle.

<The process of heat-pressing the surface material 1 and the base material 2 and the smoothness of the design surface 11a>
As shown in FIG. 5, the molded vehicle ceiling 3 has a required uneven shape like hills 3a to 3c. On the other hand, the skin material 1 and the base material 2 are plate-like before being heat-pressed (see FIG. 4). In order to form the concavo-convex shape of the molded vehicle ceiling 3, the skin material 1 and the base material 2 are deformed from a plate shape into a concavo-convex shape by being heated and pressed by a heat press. In the process of deforming the skin material 1 into a shape having a concavo-convex shape, the skin material 1 partially concentrates stress, and expands and contracts in accordance with the stress. As described above, the surface material 1 of the present embodiment suppresses the penetration of the thermosetting adhesive into the surface material 1 even if it is a part where stress is concentrated partially and expands and contracts, and The design surface 11 a can be made smooth by smoothing the unevenness according to the unevenness of the molded vehicle ceiling 3. Furthermore, the first flexible polyurethane foam 12 of the skin material 1 can provide the design surface 11a with a pleasant touch due to the cushioning property.

  The skin material 1 laminated | stacked on the base material 2 before being heated and pressurized by hot press is shown by FIG. As shown in FIG. 6, the second flexible polyurethane foam 13 of the skin material 1 is not compressed because it is before being heated and pressed by the heat press. As mentioned above, the greater the compressive residual strain, the easier it is to stagnate. Further, since the compression residual strain of the second flexible polyurethane foam 13 is relatively larger than the compression residual strain of the first flexible polyurethane foam 12, the second flexible polyurethane foam 13 is compressed more than the first flexible polyurethane foam 12. Cheap.

  For this reason, the second flexible polyurethane foam 13 is compressed as the surface material 1 is heated and pressed by the heat press. The skin material 1 laminated | stacked on the base material 2 is shown by FIG. 7 after being heated and pressurized by the hot press. As shown in FIG. 7, the second flexible polyurethane foam 13 of the skin material 1 is compressed because it is heated and pressurized. Thus, the second flexible polyurethane foam 13 of the skin material 1 is compressed as it is heated and pressurized. For this reason, the surface material 1 of the present embodiment has the following effects.

  The compression residual strain of the first flexible polyurethane foam 12 is in a relatively smaller relationship than the compression residual strain of the second flexible polyurethane foam 13. Compressive residual strain is a phenomenon generally called sag. The greater the compressive residual strain, the more likely it to sag. The compressive residual strain of the second flexible polyurethane foam 13 is relatively larger than the compressive residual strain of the first flexible polyurethane foam 12. Therefore, the second flexible polyurethane foam 13 can be compressed more than the first flexible polyurethane foam 12 in the process of heat-pressing the skin material 1 and the base material 2. Then, the second flexible polyurethane foam 13 is compressed to increase its density, and is deformed in accordance with the uneven shape of the surface material 1 to be in close contact with the surface material 1. For this reason, the second flexible polyurethane foam 13 can suppress penetration of the thermosetting adhesive from the base 2 into the interior of the skin material 1. As a result, penetration of the thermosetting adhesive into the interior of the skin material 1 can suppress the formation of irregularities on the design surface 11 a (see FIG. 1) of the surface layer 11. Further, since the flexible polyurethane foam can be flexibly expanded and contracted, the second flexible polyurethane foam 13 can smooth the unevenness of the molded vehicle ceiling 3 (see FIG. 5).

  Here, in order to form the concavo-convex shape of the molded ceiling 3 for a vehicle, the skin material 1 and the base material 2 have irregularities from a plate shape (see FIG. 4) by being heated and pressed by heat pressing. It deforms into a shape (see FIG. 5). In the process of deforming the surface material 1 into a shape having a concavo-convex shape, the stress is partially concentrated, and the surface material 1 expands and contracts in accordance with the stress. Therefore, the second flexible polyurethane foam 13 suppresses the penetration of the curable adhesive into the interior of the skin material 1 and smooths the irregularities according to the irregularities of the molded vehicle ceiling 3. It is necessary to be able to flexibly deform not only in the surface direction but also in the thickness direction. And since the 2nd flexible polyurethane foam 13 is formed with a flexible polyurethane foam, it can deform | transform flexibly not only in a surface direction but in the thickness direction. Therefore, since the second flexible polyurethane foam 13 in the skin material 1 does not have regularity or limitations in expansion and contraction in the plane direction as in the case of the conventionally used nonwoven fabric, formation of the molded ceiling 3 for a vehicle having an uneven shape Preferred. As described above, the second flexible polyurethane foam 13 suppresses the penetration of the thermosetting adhesive into the interior of the skin material 1 and smooths the unevenness according to the unevenness of the molded ceiling 3 for a vehicle. By doing this, the design surface 11a can be made smooth.

  On the other hand, the compressive residual strain of the first flexible polyurethane foam 12 is relatively smaller than the compressive residual strain of the second flexible polyurethane foam 13. Therefore, the first flexible polyurethane foam 12 is less likely to be compressed than the second flexible polyurethane foam 13 in the process of heat-pressing the surface material 1 and the base material 2. As a result, distortion does not easily occur on the surface 12 a on the surface layer 11 side of the first flexible polyurethane foam 12. Therefore, since the surface layer 11 laminated on the first flexible polyurethane foam 12 may be less likely to be distorted, the design surface 11 a of the surface layer 11 may be a smooth surface. As described above, since the first flexible polyurethane foam 12 is hard to be compressed, the design surface 11 a of the skin material 1 can be made smooth. Then, as described above, the first flexible polyurethane foam 12 and the second flexible polyurethane foam 13 prevent the thermosetting adhesive from infiltrating the interior of the skin material 1, and the molded ceiling 3 for a vehicle The design surface 11a can be made smooth by smoothing the asperities according to the asperity shape.

Next, a second flexible polyurethane foams 13, 70 ° C., compressive strain remaining when compressed 50% at 40% to 70% under the conditions of 22 hours, density 27 kg / m ³ or more 34 kg / m ³ or less Have the following characteristics: The second flexible polyurethane foam 13 is more easily compressed in the process of heat-pressing the skin material 1 and the base material 2 in a mold by having these characteristics, and is more easily expanded and contracted more flexibly. . Since the second flexible polyurethane foam 13 has a high density by being compressed, the second flexible polyurethane foam 13 further suppresses the penetration of the thermosetting adhesive from the substrate 2 into the interior of the surface material 1. It can. As a result, penetration of the thermosetting adhesive into the interior of the skin material 1 can further suppress the occurrence of irregularities on the design surface 11 a of the surface layer 11. In addition, since the second flexible polyurethane foam 13 can expand and contract more flexibly, the second flexible polyurethane foam 13 can further smooth the unevenness of the molded vehicle ceiling 3. As described above, the second flexible polyurethane foam 13 further suppresses penetration of the thermosetting adhesive into the inside, and makes the asperities smoother according to the asperity shape of the molded vehicle ceiling 3. By doing this, the design surface 11a can be made smoother.

Furthermore, the first flexible polyurethane foam 12, 70 ° C., compressive strain remaining when compressed 50% 15% 5% or more or less under the conditions of 22 hours, density 25 Kg / m ³ or more 30 Kg / m ³ or less of It has a characteristic. By having these characteristics, the first flexible polyurethane foam 12 is more difficult to be compressed in the process of heat-pressing the skin material 1 and the substrate 2 because the compressive residual strain is further smaller. For this reason, the first flexible polyurethane foam 12 has a cushioning property in the molded vehicle ceiling 3 manufactured through the process of heat-pressing the skin material 1 and the base material 2. Therefore, the first flexible polyurethane foam 12 can impart a pleasant touch to the cushioning material 1 to the surface material 1 and, in turn, can impart a pleasant touch to the design surface 11 a of the molded ceiling 3 for a vehicle. Further, since the first flexible polyurethane foam 12 is more difficult to be compressed, distortion is less likely to occur on the surface on the surface layer 11 side. Therefore, in the surface layer 11 laminated on the first flexible polyurethane foam 12, distortion is less likely to occur, so the design surface 11 a of the surface layer 11 may be a smoother surface. As described above, since the first flexible polyurethane foam 12 is more difficult to be compressed, the design surface 11a can be given a pleasant feeling by cushioning, and the design surface 11a of the surface material 1 can be made smoother.

  As mentioned above, although embodiment of this invention was described, the surface material used for the molded ceiling for vehicles of this invention is not limited to this embodiment, It can implement in other various forms. For example, in the present embodiment, a skin material used for a molded ceiling for a vehicle is described as an example of a skin material used for a molded ceiling for a vehicle, but the vehicle is not limited to a vehicle and applied to various vehicles such as ships and aircrafts. It can.

Reference Signs List 1 skin material 11 surface layer 11 a design surface 12 first soft polyurethane foam 13 second soft polyurethane foam 2 substrate 21 fiber reinforcing material 22 core material 23 fiber reinforcing material 24 non-air permeable film 25 backing material 101 gas burner 102 gas burner 103 roll 104 Roll 105 Roll 201 Forming mold 202 Forming mold 3 Molded ceiling 3a hill 3b hill 3c hill

Claims (3)

A skin material used for a molded vehicle ceiling,
A surface layer configured as a design surface facing the interior side of the vehicle;
A first flexible polyurethane foam laminated on one side of the surface layer;
And a second flexible polyurethane foam laminated on the surface opposite to the surface on which the surface layer of the first flexible polyurethane foam is laminated.
A skin material used for a molded vehicle ceiling, wherein the compressive residual strain of the first flexible polyurethane foam is relatively smaller than the compressive residual strain of the second flexible polyurethane foam. It is a skin material used for the molded ceiling for vehicles according to claim 1,
It said second flexible polyurethane foams, 70 ° C., 70% in less compressive strain remaining when compressed 50% 40% under the conditions of 22 hours, the density is a 27 kg / m ³ or more 34 kg / m ³ or less of the characteristic A surface material used for a molded ceiling for vehicles having. It is a surface material used for the molded ceiling for vehicles of Claim 1 or Claim 2, Comprising:
It said first flexible polyurethane foams, 70 ° C., compressive strain remaining when compressed 50% 15% 5% or more or less under the conditions of 22 hours, the density is a 25 Kg / m ³ or more 30 Kg / m ³ or less of the characteristic A surface material used for a molded ceiling for vehicles having.

Images