MOLDED CEILING AND ITS MANUFACTURE

PURPOSE:To obtain a molded ceiling free from a stimulating smell by improving rigidity by sticking resin felt and a skin layer to a core material into which a hole is provided. CONSTITUTION:A polyethylene film 10 is press-bonded to one side of phenol impregnated paper 8 and holes 9 having the diameter of 1-50mm are provided at density of at least 20 pieces/m by a press mold 16 provided with a plurality of protrusions, in a core material 7. A resin felt 2 is put on the same, hot press is performed at 200-240 deg.C and a base material layer 19 is molded. The base material layer 19 having temperature of 140-240 deg.C is put on a resin mold 22 with a hole and vacuum suction is performed by actuating a fan 23. A stimulating smell such as phenol or formalin contained in the resin felt 2 and phenol impregnated paper 8 is released into the air through a ventilating tube 24. Then the same is cut into a form corresponding to a ceiling, put within a cavity 27, to which hot-melt 1, wadding urethane 12 and cloth 14 are laminated and hot press is performed. When the same is cooled after that, manufacturing of the molded ceiling is completed.