JP5533288B2 - Manufacturing method of heat insulation interior material - Google Patents

Description

  The present invention relates to a method for manufacturing a heat insulating interior material. More specifically, the present invention relates to a method for manufacturing a heat insulating interior material in which a heat insulating base material is disposed in a sealed space surrounded by a first sheet material and a second sheet material and has a fastening hole.

  Conventionally, a heat insulating material is used as a kind of interior material of an automobile or the like for the purpose of temperature management in the vehicle. As this heat insulating material, a ceiling interior material disclosed in the following Patent Document 1 is known (see FIGS. 3 to 8 of Patent Document 1). The ceiling interior material of Patent Document 1 is formed by stacking a foam sheet material having shape retention, an aggregate of opened fibers, and a film material sequentially on a mold from the design surface side, and then vacuum drawing. Is done. In this ceiling interior material, the foam sheet material ensures the shape retention of the entire ceiling interior material, while preventing the uneven shape of the fibers contained in the ceiling interior material from appearing on the design surface on the foam sheet material side. It has an excellent function by having both functions.

JP 2009-143274 A

However, the foam sheet material accounts for a large proportion of the ceiling interior material in terms of weight and thickness. Therefore, the present inventors examined a heat-insulating interior material that transferred the function of the foam sheet material to other members while eliminating the foam sheet material, and demanded further reduction in weight and thickness in recent years. Attempted to respond to.
And among the said ceiling interior materials, it replaces with the aggregate | assembly of the opened fiber, and utilizes the non-molding base material (general interior base material) which has shape retention property, The said foam sheet material is used. It was found that a heat insulating interior material having excellent performance similar to the ceiling interior material can be obtained without using it. That is, a heat-insulating interior material obtained by further forming a laminate formed by sandwiching an unmolded base material having shape retaining property with a non-breathable sheet material having no shape retaining property such as a film and then evacuating it. It is. In addition, it was found that by using an unmolded base material having shape retention, a through hole can be provided in the base material, and a fastening hole can be provided in the heat insulating interior material itself using the through hole. . However, in the heat-insulating interior material obtained by the above method, the non-breathable sheet material that forms the surface against deformation of the encapsulated base material when forming a laminate obtained by evacuation Is not sufficiently followed, wrinkles in the non-breathable sheet material, and further, there is a problem that it is difficult to maintain the internal airtightness of the heat-insulated interior material due to the generation of pinholes due to wrinkles I understood.

  The present invention has been made in view of the above circumstances, and in a heat-insulating interior material in which a heat-insulating base material is disposed in a sealed space surrounded by a first sheet material and a second sheet material, the internal air-tightness is maintained. It aims at providing the heat insulation interior material which can be equipped with a fastening hole. Moreover, it aims at providing the manufacturing method of the heat insulation interior material with which it was suppressed that the local wrinkle etc. of a sheet | seat material generate | occur | produce while providing such a fastening hole.

In order to solve the above problems, a method for manufacturing a heat-insulated interior material according to claim 1 is characterized in that a heat-insulating base material is enclosed in a sealed space surrounded by a non-breathable first sheet material and a non-breathable second sheet material. The material is arranged,
In the heat insulating base material, a heat insulating base material through-hole is formed,
The first sheet material enters from one side of the heat insulating substrate into the heat insulating substrate through hole,
The second sheet material enters from the other surface side opposite to the one surface of the heat insulating base material into the heat insulating base material through hole,
The first sheet material and the second sheet material are joined in the heat insulating substrate through-hole to form a joined portion,
In the joint part, a joining part through hole is formed so as to leave at least an edge part of the joint part, and the heat insulating interior material is formed by a fastening hole in the heat insulating interior material,
A heat insulating base material forming step for forming the heat insulating base material into a predetermined shape;
A first sheet material forming step of forming the first sheet material into a shape including a portion along the shape of one surface of the heat insulating base material formed into the predetermined shape;
A second sheet material forming step of forming the second sheet material into a shape having a portion along the shape of the other surface opposite to the one surface of the heat insulating base material formed into the predetermined shape;
The heat-insulating base material formed with the heat-insulating base material through-hole is sandwiched between the molded first sheet material and the molded second sheet material, and the first sheet material and the second sheet. A surface contact step of reducing the pressure in the space sandwiched between the materials and bringing the first sheet material and the second sheet material into surface contact within the heat insulating base material through-hole,
A joining portion forming step of joining the surface-contacted portions to form the joining portion;
A joint through hole forming step of forming the joint holes in the joint, and gist Rukoto equipped with.

The manufacturing method of the heat-insulating interior material according to claim 2 is characterized in that, in claim 1, the protruding portion protruding inward of the fastening hole is formed from at least a part of the joint portion. To do.

According to a third aspect of the present invention, there is provided the method for manufacturing a heat-insulating interior material according to the second aspect, wherein in the bonding portion through hole forming step, at least a part of the bonding portion remains as the protruding portion. The gist is to form .

Method for producing a heat-insulating interior material according to claim 4, in any one of claims 1 to 3, such a junction, wherein the first sheet material and second sheet material are welded Rukoto Is the gist.

The method for producing a heat-insulating interior material according to claim 5 is the shape of one surface of the heat-insulating base material formed in the predetermined shape in the first sheet material forming step according to any one of claims 1 to 4. The gist of the present invention is a step of forming the first sheet material by adsorbing the first sheet material to a mold having a portion along the line.

The method for manufacturing a heat-insulating interior material according to claim 6 is the method according to any one of claims 1 to 5 , wherein the second sheet material forming step is performed on the other surface of the heat-insulating base material formed into the predetermined shape. The gist is that it is a step of forming the second sheet material by adsorbing the second sheet material to a mold having a portion along the shape.

The method for manufacturing a heat-insulating interior material according to claim 7 is the method according to claim 5 , wherein the mold used in the first sheet material molding step welds edge portions of the first sheet material and the second sheet material. The gist of the invention is to have a heater for heating.

The method for manufacturing a heat-insulating interior material according to claim 8 is the method according to claim 6 , wherein the mold used in the second sheet material forming step welds edge portions of the first sheet material and the second sheet material. The gist of the invention is to have a heater for heating.

According to the heat-insulating interior material according to the present method, the heat-insulating interior material in which the heat-insulating base material is arranged in the sealed space surrounded by the first sheet material and the second sheet material is provided with a fastening hole while maintaining internal airtightness. be able to.
In the heat insulation interior material by this method , when the protrusion part which protrudes toward the inner side of a fastening hole is formed from at least one part of a junction part, it is made to contact | abut to the fastening member inserted in a fastening hole By doing this, it is possible to suppress the looseness and the disconnection of the fastening member.
In the heat-insulating interior material according to the present method , when the first sheet material and the second sheet material are welded to the joint portion, an airtight space having excellent airtightness can be formed.

According to the method for manufacturing a heat-insulating interior material of the present invention, in a heat-insulating interior material in which a heat-insulating base material is arranged in a sealed space surrounded by the first sheet material and the second sheet material, fastening is performed while maintaining internal airtightness. Holes can be provided, and local wrinkles and the like of the sheet material can be suppressed while forming such fastening holes.
In the method for manufacturing a heat-insulating interior material according to the present invention, when forming the joint through-hole so that at least a part of the joint remains as a protruding portion in the joint through-hole forming step, the airtightness of the sealed space is further increased. Protruding portions can be formed while maintaining certainty.
In the method for manufacturing a heat-insulating interior material according to the present invention, a heat-insulating base material forming step for forming a heat-insulating base material into a predetermined shape, and a portion along the shape of one surface of the heat-insulating base material formed into a predetermined shape with the first sheet material The first sheet material forming step for forming into a shape having a shape, and the second sheet material into a shape having a portion along the shape of the other surface opposite to the one surface of the heat insulating base material formed into a predetermined shape A second sheet material forming step, and in the surface contact step, the formed heat insulating base material is sandwiched between the formed first sheet material and the formed second sheet material, and the first sheet material and the second sheet material When decompressing the inside of the space sandwiched between two sheet materials, it is possible to suppress the occurrence of local wrinkles and the like of the sheet material more reliably.
In the method for manufacturing a heat-insulating interior material according to the present invention, the first sheet material forming step causes the first sheet material to be adsorbed to a mold having a portion along the shape of one surface of the heat-insulating base material formed into a predetermined shape. Thus, in the process of forming the first sheet material, the first sheet material can be easily formed into a shape having a portion along the shape of one surface of the heat insulating substrate.
In the method for manufacturing a heat-insulating interior material according to the present invention, the second sheet material forming step causes the second sheet material to be adsorbed to a mold having a portion along the shape of the other surface of the heat-insulating base material formed into a predetermined shape. By this, when it is a process of shape | molding a 2nd sheet material, a 2nd sheet material can be easily shape | molded in the shape provided with the site | part along the shape of the other surface of a heat insulation base material.
In the method for manufacturing a heat-insulating interior material of the present invention, when the mold used in the first sheet material forming step has a heater for welding the edge portions of the first sheet material and the second sheet material, The edge part can be welded from the mold used in the first sheet material forming step without using a dedicated mold for welding the edge part.
In the method for manufacturing a heat-insulating interior material according to the present invention, when the mold used in the second sheet material forming step has a heater for welding the edge portions of the first sheet material and the second sheet material, Without using a dedicated die for welding the edge portion, the edge portion can be welded from the die used in the second sheet material forming step.

The present invention will be further described in the following detailed description with reference to the drawings referred to, with reference to non-limiting examples of exemplary embodiments according to the present invention. Similar parts are shown throughout the several figures.
It is sectional drawing which shows the outline of the heat insulation interior material which concerns on this method . It is explanatory drawing explaining the fastening hole vicinity of the heat insulation interior material which concerns on this method . It is explanatory drawing explaining the heat insulation base material in the vicinity of the fastening hole of the heat insulation interior material which concerns on this method . It is explanatory drawing explaining each sheet | seat material in the fastening hole vicinity of the heat insulation interior material which concerns on this method . It is explanatory drawing explaining the fastening hole vicinity of the other example of the heat insulation interior material which concerns on this method . It is explanatory drawing explaining the fastening hole vicinity of the further another example of the heat insulation interior material which concerns on this method . It is explanatory drawing explaining the fastening state using an example of the heat insulation interior material which concerns on this method . It is explanatory drawing explaining the fastening state using the other example of the heat insulation interior material which concerns on this method . It is explanatory drawing explaining the surface contact process in this method. It is explanatory drawing explaining the junction part formation process in this method. It is explanatory drawing explaining the junction part through-hole formation process in this method. It is explanatory drawing explaining the mold release performed after the junction part formation process in this method. It is explanatory drawing explaining the heat insulation description formation process in this method. It is explanatory drawing explaining the 1st sheet material formation process in this method. It is explanatory drawing explaining the 2nd sheet material formation process in this method. It is explanatory drawing explaining the edge part before a junction part through-hole formation process, a suction port, and a surface contact part. It is explanatory drawing explaining the edge part, edge part, and fastening hole after a junction part through-hole formation process. It is explanatory drawing explaining the edge part, edge part, fin part, and fastening hole after a junction part through-hole formation process. It is sectional drawing which shows the example of arrangement | positioning of an example of a heat insulation interior material.

  The items shown here are exemplary and illustrative of the embodiments of the present invention, and are the most effective and easy-to-understand explanations of the principles and conceptual features of the present invention. It is stated for the purpose of providing what seems to be. In this respect, it is not intended to illustrate the structural details of the present invention beyond what is necessary for a fundamental understanding of the present invention. It will be clear to those skilled in the art how it is actually implemented.

The heat insulation interior material by this method is the heat insulation interior material 1 in which the heat insulation base material 13 is arranged in the sealed space surrounded by the non-breathable first sheet material 11 and the non-breathable second sheet material 12. And
A heat insulating base material through hole 131 is formed in the heat insulating base material 13,
The first sheet material 11 enters the heat insulating base material through hole 131 from the one surface 13a side of the heat insulating base material 13,
The second sheet material 12 enters the heat insulating base material through hole 131 from the other surface 13b side opposite to the one surface of the heat insulating base material 13,
The first sheet material 11 and the second sheet material 12 are joined in the heat insulating substrate through-hole 131 to form a joint portion 15;
A joint through hole 152 is formed in the joint 15 so as to leave at least an edge 151 of the joint 15, and a fastening hole 16 is formed in the heat insulating interior material 1.

[1] Heat-insulating interior material Hereinafter, the heat-insulating interior material will be described (see FIGS. 1 to 8 and the like).
The “heat insulation interior material (1)” includes a first sheet material 11, a second sheet material 12, and a heat insulation base material 13. Moreover, this heat insulation interior material 1 is equipped with the sealed space 14 enclosed by the 1st sheet material 11 and the 2nd sheet material 12, and is a vacuum heat insulation interior material which has what is called a vacuum heat insulation structure.

The “first sheet material (11)” is a non-breathable sheet material, and is a member that keeps the hermetic space 14 hermetic together with the second sheet material 12. The first sheet 11 only needs to have non-breathability, that is, gas barrier properties, and other characteristics and configuration are not particularly limited. The first sheet material 11 may be composed of only one layer or may be composed of two or more layers. When it consists of only one layer, the 1st sheet material 11 which consists only of the following gas barrier layer is mentioned, for example, However, It is preferable that this 1st sheet material 11 is comprised from two or more layers. When composed of two or more layers, each layer can include a gas barrier layer, an infrared reflective layer, a vibration damping layer (sound absorbing layer), a protective layer, a welded layer, and the like. Usually, of these layers, a gas barrier layer is provided, and in addition, one or more layers other than the gas barrier layer can be provided.
Note that the gas barrier layer, infrared reflection layer, vibration damping layer (sound absorbing layer), protective layer, welding layer, and the like may have a function of two or more layers by only one layer. That is, for example, a gas barrier layer having both gas barrier ability and infrared reflection ability, an infrared reflection layer having both infrared reflection ability and gas barrier ability, and the like are also included.

  The gas barrier layer is a layer for ensuring non-breathability (that is, gas barrier properties). This gas barrier layer may include only one layer or may include two or more gas barrier layers. When two or more gas barrier layers are provided, they may be arranged as adjacent layers or may be arranged via other layers.

Further, the configuration of the gas barrier layer is not particularly limited. For example, a resin gas barrier layer made of a resin having gas barrier properties, a composite gas barrier layer including a metal layer and a support layer that supports the metal layer, and the like can be used. Examples of the resin constituting the resin gas barrier layer include resins having gas barrier properties such as ethylene-vinyl alcohol copolymer (EVOH), ethylene-vinyl acetate copolymer (EVA), polyvinyl alcohol (PVA), and polyethylene terephthalate (PET). Is mentioned. These resins may be used alone or in combination of two or more.
The ethylene content, saponification degree, and polymerization degree of the ethylene-vinyl alcohol copolymer are not particularly limited, but usually the ethylene content is 60 mol% or less (more preferably 25 to 55 mol%), and the saponification degree. Is 90 mol% or more (further 99 to 100 mol%). The same applies to the ethylene-vinyl alcohol copolymer mentioned below.

Furthermore, vapor deposition metal or metal foil etc. can be used as a metal layer among composite gas barrier layers. Examples of the metal constituting the metal layer include aluminum, copper, iron, stainless steel, nickel, gold, silver, and alloys containing two or more of these. Moreover, the layer which consists of various resin can be used as a support layer among composite gas barrier layers. Examples of the resin constituting the support layer include polyamide resins such as nylon, polyester resins such as polyethylene terephthalate (PET) and polybutylene terephthalate (PBT), and resins such as ethylene-vinyl alcohol copolymer (EVOH). These resins may be used alone or in combination of two or more. This composite gas barrier layer can exhibit infrared reflectivity described later in addition to gas barrier properties.
Although the thickness of a gas barrier layer is not specifically limited, For example, it can be set as 1-50 micrometers, 5-40 micrometers is preferable and 10-30 micrometers is more preferable.

The infrared reflection layer is a layer having the ability to reflect infrared rays irradiated to one side or the other side while suppressing transmission of infrared rays from one side to the other side. When this infrared reflective layer is provided, the heat insulating effect of the heat insulating interior material can be further improved as compared with the case where this infrared reflective layer is not provided. This infrared reflective layer may include only one layer, or may include two or more infrared reflective layers. When two or more infrared reflective layers are provided, they may be arranged as adjacent layers or may be arranged via other layers.
As the infrared reflection layer, a layer having the same configuration as the composite gas barrier layer can be used as described above. That is, a composite infrared reflection layer including a metal layer and a support layer that supports the metal layer can be used. Of the composite infrared reflective layer, as the metal layer, vapor-deposited metal or metal foil can be used. Examples of the metal constituting the metal layer include aluminum, copper, iron, stainless steel, nickel, gold, silver, and alloys containing two or more of these. Moreover, the layer which consists of various resin can be used as a support layer among composite infrared reflective layers. Examples of the resin constituting the support layer include polyamide resins such as nylon, polyester resins such as polyethylene terephthalate (PET) and polybutylene terephthalate (PBT), and resins such as ethylene-vinyl alcohol copolymer (EVOH). These resins may be used alone or in combination of two or more.
Although the thickness of an infrared reflective layer is not specifically limited, For example, it can be set as 1-50 micrometers, 5-40 micrometers is preferable and 10-30 micrometers is more preferable.

  The damping layer is a layer that has an action of absorbing or attenuating vibration. By providing the vibration damping layer, higher sound insulation can be obtained. As the damping layer, ethylene-vinyl acetate copolymer (EVA), polyvinyl alcohol (PVA), ABS resin, elastomer, rubber and the like can be used. These may use only 1 type and may use 2 or more types together. Although the thickness of a damping layer is not specifically limited, For example, it can be set to 10-1000 micrometers, 100-1000 micrometers is preferable and 200-1000 micrometers is more preferable.

  The protective layer is, for example, a layer formed from a polyamide resin such as nylon, a polyester resin such as polyethylene terephthalate or polybutylene terephthalate, or a high-strength resin such as polycarbonate (PC). When the protective layer is provided, the function of protecting the heat-insulating interior material from scratches from the outside is exhibited, and the sealed space 14 can be more effectively maintained for a long period of time. Although the thickness of a protective layer is not specifically limited, For example, it can be set to 10-50 micrometers, 15-40 micrometers is preferable and 15-30 micrometers is more preferable.

  The welded layer is a layer that is melted by heating and can be welded together. This layer is usually made of a thermoplastic resin. Although the kind of such a thermoplastic resin is not specifically limited, For example, polyolefin resins, such as polyethylene and a polypropylene, a thermoplastic elastomer, etc. can be used. These resins may be used alone or in combination of two or more. Although the thickness of a heat welding layer is not specifically limited, For example, it can be set to 10-100 micrometers, 30-100 micrometers is preferable and 30-50 micrometers is more preferable.

Various functional layers such as a gas barrier layer, an infrared reflective layer, a vibration damping layer, a protective layer, and a welded layer may be provided in any order, but among these, the gas barrier layer and the infrared reflective layer are usually The first sheet material 11 is preferably arranged on the outer side, and it is particularly preferable that the surface of the first sheet material 11 is configured. On the other hand, the welded layer is usually preferably provided as the innermost layer (side closer to the second sheet material 12).
Moreover, although the whole thickness of the 1st sheet | seat material 11 is not specifically limited, For example, it can be set as 30-2000 micrometers, 30-1000 micrometers is preferable, 50-500 micrometers is more preferable, 50-100 micrometers is still more preferable.

  The “second sheet material (12)” is a non-breathable sheet material, and is a member that keeps the hermetic space 14 hermetic together with the first sheet material 11. The second sheet 12 may be non-breathable, that is, has a gas barrier property, and other characteristics and configuration are not particularly limited. The second sheet material 12 may be composed of only one layer or may be composed of two or more layers. When it consists of only one layer, the 2nd sheet material 12 which consists only of the said gas barrier layer is mentioned, for example, However, It is preferable that this 2nd sheet material 12 is comprised from 2 or more layers. When composed of two or more layers, each layer can include a gas barrier layer, an infrared reflective layer, a vibration damping layer (sound absorbing layer), a protective layer, a welded layer, and the like. Usually, of these layers, a gas barrier layer is provided, and in addition, one or more layers other than the gas barrier layer can be provided. About each layer which can comprise these 2nd sheet | seat materials 12, each description about each layer in the said 1st sheet | seat material 11 is applied.

The gas barrier layer, infrared reflection layer, vibration damping layer (sound absorbing layer), protective layer, weld layer, etc., as in the first sheet material 11, also in the second sheet material 12, these two or more layers. The function may be provided by only one layer. That is, for example, a gas barrier layer having both gas barrier ability and infrared reflection ability, an infrared reflection layer having both infrared reflection ability and gas barrier ability, and the like are also included.
Further, the first sheet material 11 and the second sheet material 12 may be different members, or may be a single continuous sheet material.

  The “heat insulating substrate (13)” is a substrate disposed in a sealed space 14 surrounded by the first sheet material 11 and the second sheet material 12. Further, a heat insulating base material through hole 131 is formed in the heat insulating base material 13. Although the characteristic of this heat insulation base material 13 is not specifically limited, Usually, it has shape retention. Since the heat insulating base material 13 has shape retention, each sheet material can be satisfactorily followed without deformation of the heat insulating base material 13 even when pressure reduction is performed to form the sealed space 14. Furthermore, it is preferable that the heat insulation base material 13 has air permeability. This is because, when the pressure is reduced when the sealed space 14 is formed, the gas can be sucked and removed smoothly and the inside of the sealed space 14 is easily brought into a lower pressure state by having air permeability.

  As the heat insulating base material 13 having air permeability, a fiber compressed product obtained by compressing a fiber aggregate in which fibers are accumulated by a resin binder can be used. The fiber used for the fiber compressed product may be an organic fiber, an inorganic fiber, or a combination thereof. Examples of organic fibers include synthetic fibers obtained by spinning from various resins, and natural fibers obtained from plants and animals. These may be used alone or in combination of two or more. Examples of inorganic fibers include glass fibers, alumina fibers, and silica fibers. These may use only 1 type and may use 2 or more types together.

Among the various fibers described above, examples of the synthetic fiber include fibers spun using a polyolefin resin, a polyester resin, a polyamide resin, and the like, and among these, fibers spun from a polyolefin resin and a polyester resin are preferable. Among these, examples of the polyolefin resin include polyethylene and polypropylene. These may use only 1 type and may use 2 or more types together. Examples of the polyester resin include polyethylene terephthalate (PET) and polybutylene terephthalate (PBT). These may use only 1 type and may use 2 or more types together. These synthetic fibers can also function as a resin binder.
Examples of the fiber (plant fiber) obtained from the plant include fibers obtained by defibrating wood and the like, fibers collected from basts of plants such as kenaf, and the like.
Furthermore, as the resin binder, polyolefin resin, polyester resin, polyamide resin or the like can be used. Of these, polyolefin resins are preferred.

  The “heat-insulating base material through-hole (131)” (see FIG. 3) is a through-hole formed so as to penetrate between the one surface 13a and the other surface 13b of the heat-insulating base material 13. The formation position, size, planar shape, cross-sectional shape, number, and the like of the heat insulating substrate through-hole 131 are not particularly limited, but are suitable for the shape of the fastening member 32 because it is a part for forming the fastening hole 16. It is preferable. For example, the planar shape (opening shape seen from one surface 13a of the heat insulating base material 13) is circular, and the diameter thereof can be 10 to 100 mm, more preferably 10 to 50 mm, and more preferably 10 to 30 mm. preferable. Moreover, the planar shape (opening shape seen from one surface 13a of the heat insulating base material 13) is a square, and one side thereof can be 10 to 100 mm, more preferably 10 to 50 mm, and more preferably 10 to 30 mm. preferable.

  The “joining portion (15)” is a portion where the first sheet material 11 and the second sheet material 12 are joined in the heat insulating base material through hole 131 (see FIG. 10 and the like). In the joint portion 15, the first sheet material 11 enters from the one surface 13 a side of the heat insulating base material 15, and the second sheet material 12 enters from the other surface 13 b side of the heat insulating base material 15. That is, the first sheet material 11 and the second sheet material 12 are joined in the heat insulating base material through hole 131 to form the joint portion 15.

In the joint portion 15, the first sheet material 11 and the second sheet material 12 may be joined in any way, but are preferably welded.
Furthermore, when the first sheet material 11 and the second sheet material 12 are bonded by welding in the bonding portion 15, the bonding surface of the first sheet and / or the second sheet is the welding layer as described above. The sheets may be welded together, or the sheets may be welded with a welding member interposed therebetween.

  The “joining part through hole (152)” is a through hole formed in the joining part 15 (see FIG. 4). The joint through hole 152 is formed so as to leave at least the edge 151 of the joint 15 (the joint edge 115 in the first sheet material 11 and the joint edge 125 in the second sheet material 12). . The formation position, size, planar shape, cross-sectional shape, number, and the like of the joint through-hole 152 are not particularly limited, but are suitable for the shape of the fastening member 32 because it is a part for forming the fastening hole 16. It is preferable that For example, the planar shape (opening shape as viewed from the first sheet material 11 side) is circular, and the diameter thereof can be 3 to 50 mm, further 3 to 30 mm is preferable, and 5 to 20 mm is more preferable. . Moreover, the planar shape (opening shape seen from the 1st sheet | seat material 11 side) is a square, The one side can be 3-50 mm, Furthermore, 3-30 mm is preferable and 5-20 mm is more preferable. .

  The “edge (151)” is a part of the joint 15 remaining when the joint through hole 152 is formed in the joint 15. Since the edge 151 is left in the joint through hole 152, the airtightness of the sealed space 14 can be sufficiently maintained in the joint through hole 152. Further, since the edge 151 is disposed in the joint through hole 152, the edge 151 holds the fastening member 32 as illustrated in FIGS. It can prevent rattling and omission.

  Note that the edge 151 is also disposed in the heat insulating base material through hole 131 in order to drill the joint 15 formed in the heat insulating base material through hole 131. The position of the edge 151 in the heat insulating base material through-hole 131 may be close to the one surface 13a of the heat insulating base material 13 (see FIG. 5), and substantially from the one surface 13a and the other surface 13b of the heat insulating base material 13. May be equidistant (see FIG. 2), or may be closer to the other surface 13b of the heat insulating base 13 (not shown). This is because the effect of providing the edge 151 can be obtained in any of these forms.

The “fastening hole (16)” is formed by forming the heat insulating base material through hole 131 in the heat insulating base material 13 and further forming the joint portion through hole 152 in the joint portion 15 in the heat insulating base material through hole 131. The through-hole penetrated through the heat-insulating interior material 1. The formation position, size, planar shape, cross-sectional shape, number, and the like of the fastening holes 16 are not particularly limited, but are usually the same as those of the joint through holes 152.
Further, the fastening hole 16 is preferably formed with a projecting portion 161 projecting inward from at least a part of the joint portion 15 (FIGS. 2, 5, 6, 17, and 17). (See FIG. 18). The protruding portion 161 generally coincides with the edge portion 151, but may be larger than the edge portion 151. That is, for example, as illustrated in FIG. 6 and FIG. 18, in the fastening hole 16, the fastening is further performed than the edge portion 151 where the first sheet material 11 and the second sheet material 12 are joined. The first sheet material 11 and the second sheet material 12 can be provided with fin portions 162 (see FIGS. 6 and 18) that are not joined toward the inside of the hole 16. By providing the protruding portions 161 such as the edge portion 151 and the fin portion 162, the edge portion 151 holds the fastening member 32 as illustrated in FIGS. 7 and 8. Can be prevented.

  The “sealed space (14)” is a space surrounded by the first sheet material 11 and the second sheet material 12 and kept airtight. Further, the sealed space 14 is kept airtight and is normally maintained in a reduced pressure state. Although the pressure state in this sealed space 14 is not specifically limited, For example, it can be set to 10-200 Pa, 10-50 Pa is preferable and 10-20 Pa is more preferable. The sealed space 14 may be substantially filled with an insert such as the heat insulating base material 13.

In addition to the first sheet material 11, the second sheet material 12, and the heat insulating base material 13, the heat insulating interior material 1 can have other configurations. Other configurations include a skin layer (design layer), a sound absorbing felt layer, an infrared reflective layer, and the like. These other structures may use only 1 type and may use 2 or more types together.
Among these, the skin layer (design layer) constitutes the design layer of the heat-insulating interior material 1. That is, it is a layer that forms a surface that is visually recognized at a place where it is disposed as an interior material. Such a skin layer may be laminated on the first sheet material 11 side or may be laminated on the second sheet material 12 side.
The sound absorbing felt may be further laminated as a sound absorbing material, for example, on the first sheet material 11 side of the heat insulating interior material 1, or may be further laminated on the second sheet material 12 side of the heat insulating interior material 1. Good. The first sheet material 11 side is disposed on the vehicle interior side (design surface side), the second sheet material 12 side is disposed on the vehicle exterior side (back side), and the first sheet material 11 has an outer skin on the vehicle interior side. In the case of the heat insulating interior material 1 in which layers are laminated, the sound absorbing felt can be laminated between the skin layer and the first sheet material 11, on the outside of the cabin of the second sheet material 12, and the like.
Further, as the infrared absorbing layer, the infrared absorbing layer constituting each of the sheet materials can be used as it is.

The heat-insulating interior material 1 according to this method includes, for example, a first sheet material 11, a heat-insulating base material 13, a second sheet material 12, and a skin layer 17 (a surface layer constituting a design surface in the heat-insulating interior material). The roof panel 3 (metal panel) can be used as a roof trim (interior material having a design surface disposed on the passenger side in the vehicle) disposed on the vehicle interior side (see FIG. 19). Furthermore, it has the same configuration and can be used as a door trim, pillar garnish, deck board, package tray, etc. of an automobile having heat insulation.

  Further, as illustrated in FIGS. 7 and 8, the fastening member 32 is inserted into the fastening hole 16 provided in the heat-insulating interior material 1, and the fastening member 32 is disposed on the fastening portion 31 (for example, the roof panel 3). It is possible to attach the heat insulating interior material 1 to a desired site. In FIG. 7, since the edge 151 is provided in the fastening hole 16, it is possible to suppress the looseness and the removal of the fastening member 32. Further, in FIG. 8, since the fin portion 162 is provided together with the edge portion 151 in the fastening hole 16, it is possible to more effectively suppress the looseness and the removal of the fastening member 32.

[2] Method for Producing Heat-Insulating Interior Material The method for producing a heat-insulating interior material according to the present invention is a method for producing the heat-insulating interior material 1, and includes a heat-insulating base material forming step PR21 for forming the heat-insulating base material 13 into a predetermined shape. The first sheet material forming step PR22 for forming one sheet material 11 into a shape having a portion along the shape of the one surface 13a of the heat insulating base material 13 formed into a predetermined shape, and the second sheet material 12 into a predetermined shape a second sheet forming step PR23 be molded into shape with a site along the shape of the opposite side of the other surface 13b and the one surface of the insulating substrate 13 which is molded and heat-insulating substrate through hole 131 is formed molded into The heat-insulating base material 13 is sandwiched between the molded first sheet material 11 and the molded second sheet material 12 , and the space 14 formed by the first sheet material 12 and the second sheet material 12 is decompressed. and, a heat insulating substrate through hole 131 A surface contact step PR11 in which the first sheet material 11 and the second sheet material 12 are brought into surface contact with each other, a joint portion forming step PR12 in which the surface-contacted portion 15 ′ is joined to form the joint portion 15, and a joint portion 15 And a joining part through-hole forming step PR13 for forming the joining part through-hole 152.

(1) Surface contact process PR11
The “surface contact step (PR11)” (see FIG. 9) is performed by sandwiching the heat insulating base material 13 in which the heat insulating base material through-holes 131 are formed between the first sheet material 11 and the second sheet material 12 while holding the heat insulating base material. This is a step of bringing the first sheet material 11 and the second sheet material 12 into surface contact within the material through hole 131.
Although this process may be performed in any way, for example, it can be performed by the following methods (1) and (2). That is, (1) using a mold having a convex shape corresponding to the heat insulating base material through hole 131, the first sheet material 11 is moved into the heat insulating base material through hole 131 (from one surface 13a side to the other surface 13b side). ) To press the second sheet material 12 into the heat insulating base material through hole 131 (from the other surface 13b side to the one surface 13a side), and within the heat insulating base material through hole 131, the first sheet material 11 and the second sheet material 12 are pressed. A method of bringing the sheet material 12 into contact with each other and bringing them into surface contact. (2) By reducing the pressure in the space between the first sheet material 11 and the second sheet material 12, the first sheet material 11 is moved into the heat insulating base material through-hole 131 (from the one surface 13a side to the other surface 13b side). The second sheet material 12 is sucked into the heat insulating base material through hole 131 (from the other surface 13b side to the one surface 13a side), and the first sheet material 11 is sucked into the heat insulating base material through hole 131. And a method of bringing the second sheet material 12 into surface contact. Of these methods, the method (2) is preferred. In the method (2), the size and number of the heat insulating substrate through-holes 131 can be reduced without requiring a mold having a convex shape corresponding to the heat insulating substrate through-hole 131 as in the method (1). Regardless, the surface contact can be made simply and reliably.

Further, when the surface contact is made by the above method (2), that is, when the pressure is reduced, (3) the edge portion 118 of the sheet material is welded leaving the suction port 181 necessary for the pressure reduction (hereinafter simply referred to as “ After the formation of the space surrounded by the sheet material, which is also referred to as “preliminary welding step”, the space surrounded by the sheet material can be brought into surface contact by suction and pressure reduction from the suction port 181. In this case, the closed space 14 can be formed by sealing the suction port 181 by welding after decompression.
Further, (4) the whole including the first sheet material 11, the second sheet material 12, the heat insulating base material 13, etc. is placed in an environment where pressure can be reduced, and is sandwiched between the first sheet material 11 and the second sheet material 12. Surface contact can be achieved by reducing the pressure in the space under this environment. In this case, while maintaining the reduced pressure environment, the edge portions 18 (the edge portion 118 of the first sheet material and the edge portion 128 of the second sheet material) of each sheet material are welded, and the edge of the sheet material is welded. The sealed space 14 can be formed by welding the entire circumference of the edge 18.
Regardless of which of the above methods (3) and (4) is used, the pressure reduction in the sealed space 14 is not particularly limited, and the sealed space 14 is, for example, 10 to 200 Pa. 10 to 50 Pa is preferable, and 10 to 20 Pa is more preferable.

  As described above, in the case of performing surface contact by decompression, the heat insulating base material 13 formed in advance in a predetermined shape (the heat insulating base material through holes 131 and the like are formed), and one surface of the heat insulating base material 13 in advance. The 1st sheet material 11 shape | molded in the shape provided with the site | part along the shape of 13a, and the 2nd sheet material previously shape | molded in the shape provided with the site | part along the shape of the other surface 13b of the heat insulation base material 13 In the surface contact step PR11, the molded heat insulating base material 13 is sandwiched between the molded first sheet material 11 and the molded second sheet material 12, and the first sheet material 11 and the first sheet material It is preferable to depressurize the space between the two sheet materials 12. Thereby, in order to sandwich the heat insulating base material 13 by the sheet materials 11 and 12 previously formed in a shape corresponding to each surface 13a and 13b of the heat insulating base material 13, the heat insulating base material 13 has, for example, in a reduced pressure. The amount of follow-up required for each sheet material 11 and 12 is reduced in the heat insulating base material through-hole 131, each part such as a curved part, a concave part, and a convex part and the periphery thereof, and each surface 13a and 13b of the heat insulating base material 13 is reduced. The sheet materials 11 and 12 can be sufficiently followed. As a result, generation of wrinkles in the sheet materials 11 and 12 can be suppressed.

(2) Junction formation process PR12
The “joining portion forming step (PR12)” (see FIG. 10) is a step of joining the portion 15 ′ in surface contact of the first sheet material 11 and the second sheet material 12 to form the joining portion 15. In the joining portion forming step PR12, the first sheet material 11 and the second sheet material 12 may be joined in any way, but the first sheet material 11 and the second sheet material 12 are joined by welding. It is preferable. If it is joining by welding, high durability can be obtained and gas barrier properties can be maintained over a long period of time.

In the case where welding is performed in the bonding portion forming step PR12, the bonding surfaces of the first sheet and / or the second sheet may be configured by the welding layer, so that the sheets may be welded to each other. The sheets may be welded together. Of these, the former is preferred. That is, it is preferable to weld by providing a welding layer on the surfaces where the sheets face each other.
Furthermore, in this joining step, the entire surface that is in surface contact in the surface contact step PR11 may be joined, or only a part may be welded. That is, only a part is welded, that is, for example, a method of forming a joint portion in an annular shape. In the case where the annular joint portion is formed, the first sheet material 11 and the second sheet material 12 are not joined to each other on the inner side in plan view of the annular joint portion. Even in such a case, in the joint through-hole forming process PR13 described later, the edge 151 (the edge 151 in this case is an annular joint) is left, and the first sheet material 11 and the second sheet material are left. The sealed space 14 can be formed by removing the region that is not joined to the portion 12 and forming the joint through hole 152.

(3) Joining part through-hole forming step PR13
The “joining part through hole forming step (PR13)” (see FIG. 11) is a process of forming the joining part through hole 152 in the joining part 15. In this step PR13, the joint through hole 152 may be formed in any way. That is, for example, the joint through-hole 152 may be formed by punching, or the joint 151 through-hole 152 may be formed by melting the other part of the joint 15 while leaving the edge 151 using a heater. Good. Furthermore, in this process PR13, it is preferable to form the joint through-hole 152 so that at least a part of the joint 15 remains as the protruding portion 161 as described above. The protrusion 161 is as described above.

(4) Other process In the manufacturing method of the heat insulation interior material of this invention, another process is provided other than said each process. Other steps include a heat insulating base material forming step PR21 (see FIG. 13), a first sheet material forming step PR22 (see FIG. 14), and a second sheet material forming step PR23 (see FIG. 15).

(4-1) Thermal insulation base material forming step PR21
Among these, the heat insulating base material forming step PR21 is a step of forming the heat insulating base material 13 into a predetermined shape (see FIG. 13). In the case of including the heat insulating base material forming step PR21 in this method, the heat insulating base material 13 is pre-formed, so that the base material before forming to become the heat insulating base material 13 (hereinafter, also simply referred to as “precursor”, However, since it is complicated, the same reference numeral 13 as that of the heat insulating base material is used), but each sheet material is wrinkled as compared with the case where it is molded after being sandwiched between the first sheet material 11 and the second sheet material 12. It can be effectively suppressed.
The method for forming the heat insulating substrate 13 is not particularly limited, and may be formed in any manner. That is, for example, a precursor (for example, a fiber compression product) can be thermoformed and shaped. That is, for example, after the precursor is preheated outside the heat insulating base material molding die (61 and 62), it is set in a press machine (the heat insulating base material forming upper die 61 and the heat insulating base material lower die 62). It can be molded by pressing. Moreover, it can shape | mold by setting a precursor to the press die which can be heated, and performing a pressurization and a heating. Furthermore, heating may be performed in a dry state at the time of heating, but humidification such as applying steam may be performed.

(4-2) First sheet material forming step PR22
The first sheet material forming step PR22 (see FIG. 14) is a step of forming the first sheet material 11 into a shape having a portion along the shape of the one surface 13a of the heat insulating base material 13 formed into a predetermined shape. It is. By providing the first sheet material forming step PR22, the shape of the first sheet material 11 can be formed in advance so as to follow the shape of the one surface 13a of the heat insulating substrate. Thereby, in the case of performing pressure reduction as described above, the distance that the first sheet material 11 follows with respect to one surface of the heat insulating base material 13 is reduced, and the first sheet material 11 is comfortably attached to the one surface 13a of the heat insulating base material 13. The shape can be followed, and the generation of wrinkles in the first sheet material 11 can be effectively suppressed.

  In addition, the shape provided with the site | part along the shape of the one surface 13a means that the 1st sheet material 11 should just have a part along the one surface 13a of the heat insulation base material 13 at least partially. In other words, the 1st sheet | seat material 11 may have a part which is not along the one surface 13a of the heat insulation base material 13 after shaping | molding. As a part which does not follow the one surface 13a of the heat insulation base material 13, the edge part 118 required when the 1st sheet material 11 is welded with the 2nd sheet material 12 is mentioned, for example. Since this end edge part 118 covers the heat insulation base material 13 and is arrange | positioned outside the edge part of the heat insulation base material 13, in the edge part 118, the 1st sheet | seat material 11 is the heat insulation base material. The shape of the one surface 13a of 13 does not follow the shape.

  Further, the first sheet material forming step PR22 is performed by adsorbing the first sheet material 11 to a mold 21 having a portion along the shape of the one surface 13a of the heat insulating base material 13 formed into a predetermined shape. A step of forming the sheet material 11 is preferable. That is, the molding is preferably performed using a mold 21 having a portion along the shape of the one surface 13a of the heat insulating base material 13, and the mold 21 is a mold that can adsorb the first sheet material 11 by suction (hereinafter, referred to as a mold 21). And simply referred to as “adsorption type”). Therefore, the mold 21 can include the suction hole 212 as illustrated in FIG.

  In the first sheet material forming step PR22, a dedicated mold for forming only the first sheet material 11 can be used, but the mold 21 is an adsorption mold and includes a portion along the shape of the one surface 13a. The first sheet material 11 can be quickly and easily formed by adsorbing the first sheet material 11 to the adsorption-type surface. For this reason, the 1st sheet | seat material 11 can be shape | molded with simple facilities with few processes.

  In the first sheet material forming step PR22, when an adsorption mold is used, the first sheet material 11 is heated before the first sheet material 11 is adsorbed to the adsorption mold, and the first sheet material 11 is flexible. Can be improved. That is, a first sheet material preheating step of preheating the first sheet material 11 can be provided before the first sheet material forming step PR2.

Furthermore, as described above, when the pressure in the space between the first sheet material 11 and the second sheet material 12 is reduced, the edge portion 118 of the first sheet material 11 and the end of the second sheet material 12 are used. In the case where welding is performed by welding the both edge portions 18 of the edge portion 128 (this step is referred to as “end edge portion welding step”), the end edge portion 118 of the first sheet material 11 is heated so as to be weldable. The heater 211 can be provided in the mold 21.
Since the mold 21 includes the heater 211, the processes from the first sheet material forming process PR2 to the edge portion welding process can be performed consistently using the mold 21. Therefore, it is not necessary to use individual molds specialized for each process, and it is not necessary to move the first sheet material 11 between the molds, and the heat-insulated interior material 1 is manufactured with a simpler equipment with a smaller number of processes. be able to.

Moreover, this 1st sheet material formation process PR22 may be performed after the heat insulation base-material formation process PR21, and may be performed before the heat insulation base-material formation process PR21. Further, the first sheet material forming step PR22 may be performed before the second sheet material forming step PR23, may be performed simultaneously with the second sheet material forming step PR23, or after the second sheet material forming step PR23. You may go. As a result, if the surface contact process PR11 is performed in a state where the first sheet material 11, the second sheet material 12, and the heat insulating base material 13 are all formed, the sheet material is prevented from being wrinkled. This is because the purpose can be achieved.
In addition, when performing 1st sheet material formation process PR22 before heat insulation base material formation process PR21, it is provided with the site | part along the shape of the one surface 13a of the heat insulation base material 13 in which the shape shape | molded previously is known. The first sheet material 11 is formed.

(4-3) Second sheet material forming step PR23
The second sheet material forming step PR23 (see FIG. 15) is a step of forming the second sheet material 12 into a shape having a portion along the shape of the other surface 13b of the heat insulating base material 13 formed into a predetermined shape. is there. By providing the second sheet material forming step PR23, the shape of the second sheet material 12 can be formed in advance so as to follow the shape of the other surface 13b of the heat insulating base material. Thereby, in the case where pressure reduction is performed as described above, the distance that the second sheet material 12 follows the other surface of the heat insulating base material 13 is reduced, and the second sheet material 12 is comfortably attached to the other surface of the heat insulating base material 13. It can be made to follow the shape of 13b and generation | occurrence | production of the wrinkle in the 2nd sheet material 12 can be suppressed effectively.

  In addition, the shape provided with the site | part along the shape of the other surface 13b means that the 2nd sheet material 12 should just have a part along the other surface 13b of the heat insulation base material 13 at least partially. In other words, the second sheet material 12 may have a portion that is not along the other surface 13b of the heat insulating base material 13 after molding. As a part which does not follow the other surface 13b of the heat insulation base material 13, the edge part 128 required when the 2nd sheet material 12 is welded with the 1st sheet material 11, for example is mentioned. Since this end edge part 128 covers the heat insulation base material 13 and is arrange | positioned outside the edge part of the heat insulation base material 13, in the edge part 128, the 2nd sheet material 12 is the heat insulation base material. The shape of the other surface 13b of 13 does not follow.

  Further, the second sheet material forming step PR23 is performed by adsorbing the second sheet material 12 to the mold 22 having a portion along the shape of the other surface 13b of the heat insulating base material 13 formed into a predetermined shape. The step of forming the two-sheet material 12 is preferable. That is, the molding is preferably performed using a mold 22 having a portion along the shape of the other surface 13b of the heat insulating base material 13, and the mold 22 is an adsorption mold that can adsorb the second sheet material 12 by adsorption. It is preferable that Furthermore, the mold 22 is preferably an adsorption mold that can adsorb the second sheet material 12 by suction. Therefore, the mold 22 can include a suction hole 222 as illustrated in FIG.

  In the second sheet material molding step PR23, a dedicated mold for molding only the second sheet material 12 can be used, but the mold 22 is an adsorption mold and has a portion along the shape of the other surface 13b. Thus, the second sheet material 12 can be quickly and easily formed by adsorbing the second sheet material 12 to the adsorption-type surface. For this reason, the 2nd sheet | seat material 12 can be shape | molded with few facilities and simple facilities.

  In the second sheet material forming step PR23, when an adsorption mold is used, the second sheet material 12 is heated before the second sheet material 12 is adsorbed to the adsorption mold, and the second sheet material 12 is flexible. Can be improved. That is, a second sheet material preheating step of preheating the second sheet material 12 can be provided before the second sheet material forming step PR23.

Furthermore, as described above, when the pressure in the space between the first sheet material 11 and the second sheet material 12 is reduced, the edge portion 118 of the first sheet material 11 and the end of the second sheet material 12 are used. When performing the above-mentioned edge part welding process of welding both edge parts 18 of the edge part 128, a heater 221 for heating the edge part 128 of the second sheet material 12 so as to be weldable is provided in the mold 22. Can be provided.
Since the mold 22 includes the heater 221, the processes from the second sheet material forming process PR 23 to the edge portion welding process can be performed consistently using the mold 22. Therefore, it is not necessary to use individual molds specialized for each process, and it is not necessary to move the second sheet material 12 between the molds, and the heat-insulating interior material 1 is manufactured with simpler equipment with a smaller number of processes. be able to.
Furthermore, when the mold 21 for forming the first sheet material 11 includes the heater 211 and the mold 22 for forming the second sheet material 12 includes the heater 221, the first sheet material forming process PR22 is started. The surface contact process 11 (including the pressure reducing process) and the process up to the edge welding process can be performed consistently using these molds 21 and 22, and in particular, the heat-insulating interior material 1 can be efficiently processed. Manufacturing can be performed.

Moreover, this 2nd sheet material formation process PR23 may be performed after the heat insulation base-material formation process PR21, and may be performed before the heat insulation base-material formation process PR21. Further, the second sheet material forming step PR23 may be performed before the first sheet material forming step PR22, may be performed simultaneously with the first sheet material forming step PR22, or after the first sheet material forming step PR22. You may go. As a result, if the surface contact process PR11 is performed in a state where the first sheet material 11, the second sheet material 12, and the heat insulating base material 13 are all formed, the sheet material is prevented from being wrinkled. This is because the purpose can be achieved.
In addition, when performing 2nd sheet material formation process PR23 before the heat insulation base material formation process PR21, it has the site | part along the shape of the other surface 13b of the heat insulation base material 13 in which the shape shape | molded previously is known. The second sheet material 12 is formed as described above.

  Thus, in the case of including the heat insulating base material forming step PR21, the first sheet material forming step PR22, and the second sheet material forming step PR23, in this method, the heat insulating base material formed in the surface contact step PR11 is used. 13 is a step of sandwiching the molded first sheet material 11 and the molded second sheet material 12 and decompressing the space between the first sheet material 11 and the second sheet material 12. it can.

  As illustrated in FIG. 9, when the surface contact process PR <b> 11 is performed under reduced pressure (reduced pressure by suction from the suction port 181 in FIG. 9), the surface contact is performed and then illustrated in FIG. 12. In addition, normally, the suction port 181 is closed to complete the sealed space 14, and the mold is released (PR31). That is, as described above, when the space between the first sheet material 11 and the second sheet material 12 is depressurized, the edge portion 118 of the first sheet material 11 and the end of the second sheet material 12 are used. In the case of adopting an edge welding step performed by welding both edge portions 18 of the edge portion 128, in this edge welding step, the edge portion 118 of the first sheet material 11 and the second sheet material 12 are used. The suction port 181 that is not yet welded in the end edge portion 18 is welded to complete the sealed space 14.

  When the suction port 181 is welded, the end edge portion 118 of the first sheet material 11 and the end edge portion 128 of the second sheet material 12 are directly in contact with each other as in the case of welding except the suction port 181. Both of them may be welded together. For example, a welding member or the like is interposed between the end edge portion 118 of the first sheet material 11 and the end edge portion 128 of the second sheet material 12. Also good. As a welding member, the material which can comprise the welding layer in the 1st sheet material 11 and the 2nd sheet material 12 can be used similarly. That is, the welding member is a layer that can be fused by heating to weld the first sheet material 11 and the second sheet material 12. This welding member is usually made of a thermoplastic resin. Although the kind of such a thermoplastic resin is not specifically limited, For example, polyolefin resins, such as polyethylene and a polypropylene, a thermoplastic elastomer, etc. can be used. These resins may be used alone or in combination of two or more.

  Moreover, although the welding conditions etc. in an edge part like-attaching process are not specifically limited, Usually, heating and pressurization are performed. Although the heating temperature (temperature in the edge part 18 to weld) at the time of welding is not specifically limited, Usually, it is 150-180 degreeC. At a temperature in this range, only the welding layer and the welding member are melted, and the other layers constituting the first sheet 11 and the second sheet 12 and the material forming the heat insulating base material 13 are affected. And welding can be performed. Furthermore, although the pressurization pressure at the time of welding (pressure in the edge part 18 to weld) is not specifically limited, Usually, it is 50-300 kPa, 100-300 kPa is preferable and 200-300 kPa is more preferable.

Hereinafter, the present invention will be described more specifically with reference to the drawings. In this example, as shown in FIGS. 1 and 19, the first sheet material 11, the heat insulating substrate 13, the second sheet material 12, and the skin layer 17 (the heat insulating interior material) are used as the heat insulating interior material according to the present method . And a roof trim having a heat insulating property (design surface disposed on the passenger side in the vehicle) provided on the inner side of the roof panel 3 (metal panel) of the automobile. It is illustrated using an interior material.

<1> 1st sheet material 11, 2nd sheet material 12, and heat insulation base material 13
The following materials were used in carrying out the method for producing a heat-insulating interior material of the example. That is,
(1) First sheet material 11 and second sheet material 12
(1a) 15 μm-thick nylon sheet, (1b) 12 μm-thick polyethylene terephthalate sheet on which aluminum is deposited, from one side (outer surface side of the heat-insulating interior material) to the other side (sealed space 14 side), 1c) 12 μm-thick ethylene-virnialcohol copolymer layer (function as a gas barrier layer, product name “EVAL”, manufactured by Kuraray Co., Ltd.) on which aluminum is deposited, (1d) 50 μm-thick polyethylene resin layer (as a welding layer) Function), a first sheet material 11 and a second sheet material 12 having a multilayer structure.
(2) Insulating base material 13
A plate material having a thickness of 3 to 5 mm made of a compressed fiber containing polypropylene fiber and glass fiber.

<2> Thermal insulation base material forming step PR21 (see FIG. 13)
The heat insulating base material 13 prepared in the above <1> was preheated to a temperature of 200 ° C., and then formed into a dome shape as a roof trim and provided with a through hole 131 using a cold press die. By this molding, the heat insulating base material through hole 131 is formed in the heat insulating base material 13. Furthermore, after releasing, unnecessary portions were cut off and removed. The obtained heat insulating base material 13 is formed smaller than these sheet materials so that the end edge portion 118 of the first sheet 11 and the end edge portion 128 of the second sheet 12 can be welded.

<3> First sheet material forming step PR22 (see FIG. 14)
The shape of the one surface 13a of the heat insulating base material 13 which is the upper die 21 of the cold press die and has the suction hole 212 and has an inner surface that can be sucked and adsorbed, and the inner surface is molded in the above <2>. The first sheet material 11 prepared in the above <1> was preheated to a temperature of 150 ° C. and adsorbed on the inner surface of the mold provided with a portion along the shape.

<4> Second sheet material forming step PR23 (see FIG. 15)
The lower die 22 of the cold press mold has a suction hole 212 and has an inner surface that can be sucked and adsorbed, and this inner surface is formed on the other surface 13b of the heat insulating base material 13 formed in the above <2>. The second sheet material 12 prepared in the above <1> was preheated to a temperature of 150 ° C. and molded by adsorbing the inner surface of the mold having a portion along the shape.

<5> Surface contact process PR11 (see FIG. 9)
In this surface contact step PR11, first, the above <2> so that the edge portion 128 of the second sheet material 12 is exposed on the second sheet material 12 in the state molded in <4>. The heat-insulating base material 13 molded in step 1 was placed.
Then, the preliminary welding process was performed. In the pre-welding process, the edge 118 of the first sheet material 11 and the edge 128 of the second sheet material 12 are welded to the sheet material by leaving the suction port 181 necessary for pressure reduction during the surface contact. An enclosed space (not a sealed space) was formed. At the time of this welding, the welding was performed with the suction port 181 being left without welding the edge portion having a width of 5 mm (see FIG. 16). Further, this welding is performed using the heater 211 attached to the edge of the upper die 21 and the heater 221 attached to the edge of the lower die 22, and each edge 118 and 128 is attached to the edge of the upper die 21. The upper and lower molds 21 and 22 were clamped while being heated to a temperature of 170 ° C.
Next, suction is performed from the space surrounded by the first sheet material 11 and the second sheet material 12 from the suction port 181 left in the preliminary welding process, and the first sheet material 11 and the second sheet material 12 are surrounded. By reducing the pressure of the space to 20 Pa, the first sheet material 11 and the second sheet material 12 were brought into surface contact within the heat insulating base material through-hole 131.

<6> Edge edge welding process and mold release (see FIG. 12)
In <5>, in the state where the space surrounded by the first sheet material 11 and the second sheet material 12 is depressurized, the heater 211 is attached to the edge of the upper mold 21 with the suction port 181. And the heater 221 attached to the edge of the lower mold 22 is used for welding, and the entire periphery of the edge 118 of the first sheet material 11 and the edge 128 of the second sheet material 12 is welded. By forming the end edge portion 18, the sealed space 14 was formed to obtain the heat insulating interior material 1. In this welding as well, the upper and lower molds 21 and 22 were clamped with the end edges 118 and 128 heated to a temperature of 170 ° C.

<7> Junction forming step PR12 (see FIG. 10)
The heat insulating base material having the heat insulating base material through-hole 131 in the sealed space 14 which is separated from the above <6> and is surrounded by the first sheet material 11 and the second sheet material 12 and kept airtight. 13 is disposed, and the first sheet material 11 and the second sheet material 12 are partially drawn into the heat insulating base material through-hole 131 and are in surface contact with each other in the hole 1 ′. The junction formation process PR12 was performed. That is, a portion 15 ′ in which a part of each of the first sheet material 11 and the second sheet material 12 is drawn into the heat insulating substrate through-hole 131 and is in surface contact with the hole is heated on the first sheet material 11 side. It was sandwiched and welded by a heater (heater for bonding portion) 231 and a heater (heater for bonding portion) 232 on the second sheet material 12 side. Also in this welding, the mold was clamped while being heated to a temperature of 170 ° C. for welding.

<8> Joining part through-hole forming step PR13 (see FIG. 11)
The joint 15 of the integrated object 1 ′ formed with the joint 15 obtained in the above <7> is punched using a punch with a diameter of 6 mm, leaving the edge 151, and the joint through hole 152 (opened) is opened. A circular shape having a diameter of 6 mm was formed to complete the fastening hole 16, and the heat-insulating interior material 1 by this method was obtained.

<9> Effect of Example As described above, in the method for manufacturing a heat insulating interior material of the present example, a sheet is provided by including the heat insulating base material forming step PR21, the first sheet material forming step PR22, and the second sheet material forming step PR23. The materials 11 and 12 can be previously formed into shapes corresponding to the surfaces 13 a and 13 b of the heat insulating base material 13. And, in order to sandwich the heat insulating base material 13 by the sheet materials 11 and 12 previously formed in a shape corresponding to each surface 13a and 13b of the heat insulating base material 13, in the surface contact step PR11, the heat insulating base material 13 has, In the heat insulating base material through hole 131 and the periphery thereof, the amount of follow-up required for each sheet material 11 and 12 is reduced, while sufficiently following each sheet material 11 and 12 against each surface 13a and 13b of the heat insulating base material 13, The first sheet material 11 and the second sheet material can be drawn into the heat insulating substrate through-hole 131 and brought into surface contact. As a result, it is possible to suppress wrinkling of the sheet materials 11 and 12 while obtaining the surface contact.

  Further, the first sheet material forming step PR22 causes the first sheet material 11 to be adsorbed to the mold 21 having a portion along the shape of the one surface 13a of the heat insulating base material 13 formed into a predetermined shape. Since this is a step of forming the sheet material 11, the sheet material 11 can be simply formed by simply adsorbing the first sheet material 11 to the mold 21. Furthermore, as illustrated in FIGS. 9, 14, and 15, in the surface contact step PR <b> 11, the same mold as the mold 21 used when sandwiching the heat insulating base material 13 can be used. For this reason, it is not necessary to separately use a dedicated mold for forming the first sheet material 11 and a dedicated mold for sandwiching the heat insulating base material 13 between the sheet materials 11 and 12. The number of processes can be reduced, and the heat insulating interior material 1 can be manufactured more efficiently.

  Further, the second sheet material forming step PR23 is performed by adsorbing the second sheet material 12 to the mold 22 having a portion along the shape of the other surface 13b of the heat insulating base material 13 formed into a predetermined shape. Since the two-sheet material 12 is formed, the second sheet material 12 can be simply formed by simply adsorbing the second sheet material 12 to the mold 22. Furthermore, as illustrated in FIGS. 9, 14, and 15, in the surface contact step PR <b> 11, the same mold as the mold 22 used when sandwiching the heat insulating base material 13 can be used. For this reason, it is not necessary to separately use a dedicated mold for forming the second sheet material 12 and a dedicated mold for sandwiching the heat insulating base material 13 between the sheet materials 11 and 12, and perform a plurality of processes with one mold. The number of processes can be reduced, and the heat insulating interior material 1 can be manufactured more efficiently.

  Moreover, both 21st sheet | seat material formation process PR22 and 2nd sheet | seat material formation process PR23 were equipped with the type | molds 21 and 22 provided with the site | part along the shape of each surface 13a and 13b of the heat insulation base material 13 shape | molded by the predetermined shape. Since the sheet materials 11 and 12 are formed by adsorbing the sheet materials 11 and 12 to each other, the sheet materials 11 and 12 are set to 1 as illustrated in FIGS. It can be formed by adsorbing the upper die and the lower die of two press machines separately. Thereby, 1st sheet material shaping | molding process PR22 and 2nd sheet material shaping | molding process PR23 can be collectively performed using one press, and the heat insulation interior material 1 can be manufactured efficiently.

In order to have the heater 211 for welding the edge part 18 to the mold 21 used in the first sheet material molding process PR22, the first sheet material molding process PR22, the surface contact process PR11, and the edge part welding process. Each process can be performed using the same mold 21, and a heat-insulating interior material can be manufactured efficiently.
Furthermore, since it has the heater 221 for welding the edge part 18 to the mold 22 used in the second sheet material forming process PR23, the second sheet material forming process PR23, the surface contact process PR11, and the edge part welding. Each process can be performed using the same mold 22, and the heat-insulating interior material can be efficiently manufactured.
Therefore, as illustrated in FIG. 9, by using the mold 21 as the upper mold, the mold 22 as the lower mold, and the upper and lower molds of one press machine, the heat insulating interior material can be manufactured particularly efficiently.

  The foregoing examples are for illustrative purposes only and are not to be construed as limiting the invention. Although the invention has been described with reference to exemplary embodiments, it is to be understood that the language used in the description and illustration of the invention is illustrative and exemplary rather than limiting. As detailed herein, changes may be made in its form within the scope of the appended claims without departing from the scope or spirit of the invention. Although specific structures, materials and examples have been referred to in the detailed description of the invention herein, it is not intended to limit the invention to the disclosure herein, but rather, the invention is claimed. It covers all functionally equivalent structures, methods and uses within the scope.

  The present invention is not limited to the embodiments described in detail above, and various modifications or changes can be made within the scope of the claims of the present invention.

1; heat-insulating interior material, 1 '; heat-insulating interior material before formation of fastening holes,
11; 1st sheet material, 115; Joining part (joining edge part), 118; End edge part,
12; 2nd sheet material, 125; Joining part (joining edge part), 128; End edge part,
13; heat insulation substrate, 13a; one surface of heat insulation substrate, 13b; other surface of heat insulation substrate, 131; heat insulation substrate through-hole,
14; sealed space,
15; junction, 15 ′; surface contact portion, 151; edge, 152; junction through hole,
16; fastening hole; 161; protrusion; 162; fin;
17; epidermis layer,
18; edge, 181; suction port,
21; 1st sheet material shaping | molding die, 211; Heating heater (for edge parts), 212; Suction hole,
22; second sheet material mold, 221; heater (for edge), 222; suction hole,
231; Heating heater (for bonding portion), 232; Heating heater (for bonding portion),
3; roof panel, 31; fastening portion, 32; fastening member,
4; Interior material,
61; Upper mold for molding a heat-insulating base material; 62; Lower mold for molding a heat-insulating base material.

Claims (8)

A heat-insulating base material is disposed in a sealed space surrounded by the non-breathable first sheet material and the non-breathable second sheet material;
In the heat insulating base material, a heat insulating base material through-hole is formed,
The first sheet material enters from one side of the heat insulating substrate into the heat insulating substrate through hole,
The second sheet material enters from the other surface side opposite to the one surface of the heat insulating base material into the heat insulating base material through hole,
The first sheet material and the second sheet material are joined in the heat insulating substrate through-hole to form a joined portion,
In the joint part, a joining part through hole is formed so as to leave at least an edge part of the joint part, and the heat insulating interior material is formed by a fastening hole in the heat insulating interior material,
A heat insulating base material forming step for forming the heat insulating base material into a predetermined shape;
A first sheet material forming step of forming the first sheet material into a shape including a portion along the shape of one surface of the heat insulating base material formed into the predetermined shape;
A second sheet material forming step of forming the second sheet material into a shape having a portion along the shape of the other surface opposite to the one surface of the heat insulating base material formed into the predetermined shape;
The heat-insulating base material formed with the heat-insulating base material through-hole is sandwiched between the molded first sheet material and the molded second sheet material, and the first sheet material and the second sheet. A surface contact step of reducing the pressure in the space sandwiched between the materials and bringing the first sheet material and the second sheet material into surface contact within the heat insulating base material through-hole,
A joining portion forming step of joining the surface-contacted portions to form the joining portion;
A method of manufacturing a heat-insulating interior material , comprising: a joint through hole forming step of forming the joint through hole in the joint . The manufacturing method of the heat insulation interior material of Claim 1 in which the protrusion part which protrudes toward the inner side of the said fastening hole is formed from at least one part of the said junction part. The method for manufacturing a heat-insulating interior material according to claim 2 , wherein in the joint through-hole forming step, the joint through-hole is formed so that at least a part of the joint remains as the protrusion. The said joining part is a manufacturing method of the heat insulation interior material in any one of the Claims 1 thru | or 3 by which the said 1st sheet material and the said 2nd sheet material are welded. In the first sheet material forming step, the first sheet material is adsorbed by a mold having a portion along the shape of one surface of the heat insulating base material formed into the predetermined shape. The method for manufacturing a heat-insulating interior material according to any one of claims 1 to 4, wherein the method is a step of molding a heat insulating material. In the second sheet material forming step, the second sheet material is adsorbed to a mold having a portion along the shape of the other surface of the heat insulating base material formed into the predetermined shape, thereby the second sheet material. The method for producing a heat-insulating interior material according to any one of claims 1 to 5, which is a step of molding a material. The method for manufacturing a heat-insulating interior material according to claim 5 , wherein the mold used in the first sheet material forming step has a heater for welding edge portions of the first sheet material and the second sheet material. . The manufacturing method of the heat insulation interior material of Claim 6 with which the said type | mold used for a said 2nd sheet material formation process has a heater for welding the edge part of a said 1st sheet material and a said 2nd sheet material. .

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