US 12,138,901 B2
Molded ceiling material for vehicle and production method therefor
Masahiko Mikami, Hiroshima (JP)
Assigned to Sanwa Kogyo Co., Ltd., Hiroshima (JP)
Filed by Sanwa Kogyo Co., Ltd., Hiroshima (JP)
Filed on Aug. 10, 2021, as Appl. No. 17/398,608.
Application 17/398,608 is a continuation of application No. PCT/JP2020/003189, filed on Jan. 29, 2020.
Claims priority of application No. 2019-026856 (JP), filed on Feb. 18, 2019.
Prior Publication US 2022/0016868 A1, Jan. 20, 2022
Int. Cl. B32B 5/24 (2006.01); B32B 5/02 (2006.01); B32B 5/18 (2006.01); B32B 5/26 (2006.01); B32B 7/02 (2019.01); B32B 7/12 (2006.01); B32B 37/12 (2006.01); B32B 37/24 (2006.01); B60R 13/02 (2006.01); D21H 13/24 (2006.01); D21H 13/40 (2006.01); D21H 27/36 (2006.01)
CPC B32B 5/245 (2013.01) [B32B 5/022 (2013.01); B32B 5/18 (2013.01); B32B 5/266 (2021.05); B32B 7/02 (2013.01); B32B 7/12 (2013.01); B32B 37/12 (2013.01); B32B 37/24 (2013.01); B60R 13/0212 (2013.01); D21H 13/24 (2013.01); D21H 13/40 (2013.01); D21H 27/36 (2013.01); B32B 2250/05 (2013.01); B32B 2260/023 (2013.01); B32B 2260/028 (2013.01); B32B 2260/046 (2013.01); B32B 2262/0276 (2013.01); B32B 2262/101 (2013.01); B32B 2262/108 (2013.01); B32B 2262/144 (2021.05); B32B 2266/0278 (2013.01); B32B 2305/022 (2013.01); B32B 2305/07 (2013.01); B32B 2305/28 (2013.01); B32B 2305/72 (2013.01); B32B 2307/546 (2013.01); B32B 2307/718 (2013.01); B32B 2310/0418 (2013.01); B32B 2315/085 (2013.01); B32B 2315/14 (2013.01); B32B 2367/00 (2013.01); B32B 2375/00 (2013.01); B32B 2605/08 (2013.01)] 9 Claims
OG exemplary drawing
 
1. A vehicular formed ceiling material disposed on an in-cabin side of a roof panel of a vehicle and having a ceiling material body in the form of a panel, the ceiling material body comprising:
a substrate layer formed from rigid urethane foam;
a first fiber-reinforced layer formed through curing a first adhesive applied, and provided on an in-cabin side of the substrate layer;
a second fiber-reinforced layer formed through curing a second adhesive applied, and provided on a roof panel side of the substrate layer;
a surface layer bonded to an in-cabin side of the first fiber-reinforced layer using the first adhesive; and
a back layer bonded to a roof panel side of the second fiber-reinforced layer using the second adhesive,
wherein the first fiber-reinforced layer includes a first mat material obtained by accumulating randomly a number of chopped strands formed from glass filaments or basalt filaments into the shape of a mat to combine into one piece using a binder,
wherein the second fiber-reinforced layer includes a paper material formed from glass filaments or basalt filaments, the paper material overlaying the substrate layer, and a second mat material obtained by accumulating randomly a number of chopped strands formed from glass filaments or basalt filaments into the shape of a mat to combine into one piece using a binder, the second mat material overlaying an opposite side of the paper material from the substrate layer.