JP2004284246A - Fiber composite resin article and its production method - Google Patents
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Abstract
Description
【０００１】
【発明の属する技術分野】
本発明は、繊維複合樹脂品、すなわち繊維材料と熱可塑性樹脂とを複合した生成品に関する。また特に本発明は、天然由来繊維と天然由来樹脂とを複合した繊維複合樹脂品に関する。
【０００２】
【従来の技術】
従来の繊維複合樹脂品は、繊維材料と熱硬化性樹脂とを組み合わせ、これを金型内で加熱加圧成型することによって得られている。
【０００３】
また繊維複合樹脂品を、繊維材料と熱可塑性樹脂との組み合わせから得ることも知られている。この場合には、繊維材料と熱可塑性繊維との組み合わせをコンタクトヒーターで加熱して樹脂分を溶解させ、その後で冷間プレスにおいて加圧成型することによって繊維複合樹脂品を得ている。
【０００４】
これらの繊維複合樹脂品は、住宅用の壁材、床材、床下の衝撃吸収及び断熱材、並びに自動車内装材、例えばドアトリム基材、インナーパネル、ピラーガーニッシュ、リヤパッケージ、天井基材、衝撃吸収材、及び吸音材等として使用されている。
【０００５】
また近年では、廃棄時の環境負荷を軽減する生分解性繊維ボード（繊維複合樹脂品）として、天然繊維と熱可塑性のセルロース系生分解プラスチックとを組み合わせた繊維ボードが開示されている（特許文献１）。
【０００６】
しかしながら特許文献１の繊維ボードでは繊維が繊維ボードの表面に露出しているので、繊維ボードにふれたときのチクチクとした感じがし、また繊維ボードに接触する織物、不織布などとの絡まり又は引っ掛かりをもたらす。ここでこの繊維ボードに接触する織物、不織布などとしては、繊維ボードの上に敷くカーペット、セーターのような衣類を挙げることができる。
【０００７】
【特許文献１】
特開２０００−１２７１１７号公報
【０００８】
【発明が解決しようとする課題】
本発明では、充分な強度及び平滑な表面を同時に有する繊維複合樹脂品を提供する。従来技術の問題を解決して平滑な表面を有する繊維複合樹脂品を得るためには、樹脂の含有率を増加させて繊維の露出を抑えることが考えられる。しかしながら熱可塑性樹脂を使用する場合、樹脂の割合を増加させると、成型時にコンタクトヒーター、冷間プレスの金型等への樹脂の付着をもたらし、繊維の露出を抑えることができない。また成型不良を起こす可能性もある。そこで本発明では、金型等への樹脂の付着及び成型不良の問題を避けつつ、従来技術の問題を解決する繊維複合樹脂品を提供する。
【０００９】
【課題を解決するための手段】
本発明は、上記問題点を解決する繊維複合樹脂品であって、第１の繊維と第１の熱可塑性樹脂との複合材料の基体層、及びこの基体層上の第２の繊維と第２の熱可塑性樹脂との複合材料の表面層を有する繊維複合樹脂品である。ここでこの第２の繊維の最大繊維径は第１の繊維の最大繊維径よりも小さく、例えば２分の１以下、特に１０分の１以下である。本発明の１つの態様では、第１の繊維の繊維径が１ｍｍ以下であり、且つ第２の繊維の繊維径が５０μｍ以下、特に１５〜３０μｍである。尚、本明細書の記載において用語「繊維複合樹脂品」は、繊維材料と樹脂との複合材料をいうものとする。また用語「繊維径」は、顕微鏡で観察される繊維の直径をいうものとする。
【００１０】
本発明のこの繊維複合樹脂品によれば、成型時の問題を避けつつ、基体層の比較的粗い繊維によって充分な強度を得て、表面層の細かい繊維によって平滑な表面を得ることができる。
【００１１】
また本発明の繊維複合樹脂品は、第１の繊維と第１の熱可塑性樹脂との複合材料の基体層、及びこの基体層上の第２の繊維と第２の熱可塑性樹脂との複合材料の表面層を有する繊維複合樹脂品である。ここでこの第１の繊維は、比較的剛性の繊維、例えばガラス、ケナフ、麻、竹、木材パルプ、やし殻及びいぐさからなる群より選択され、且つ前記第２の繊維は、比較的柔軟な繊維、例えばレーヨン、木綿、羊毛、麦わら、ポリエステル、絹、ナイロン及びウールからなる群より選択される。本発明の１つの態様では、第１の繊維がケナフ繊維であり、且つ第２の繊維がレーヨン繊維である。
【００１２】
この繊維複合樹脂品によれば、成型時の問題を避けつつ、基体層の比較的剛性の繊維によって充分な強度を得て、表面層の比較的柔軟な繊維によって平滑な表面を得ることができる。
【００１３】
本発明の１つの態様では、第１と第２の熱可塑性樹脂は同じ樹脂である。
【００１４】
この態様によれば、基体層と表面層との適合性を改良することができる。
【００１５】
本発明の１つの態様では、第１及び第２の繊維が共に天然由来繊維であり、且つ前記第１及び第２の熱可塑性樹脂が共に天然由来樹脂である。本発明の繊維及び樹脂は共に、生分解性材料であってもよい。
【００１６】
この態様によれば、全体として天然由来材料によって作ることができ、これによって環境負荷を小さくできるという利点を有する。ここで、「天然由来」とは、植物又は動物性の原料に基づき、石油系の物質を主な原料としないものをいう。また全体として生分解性材料で作った場合には、廃棄の際に生分解処理を行うことも可能になる。
【００１７】
本発明の１つの態様では、第１及び第２の熱可塑性樹脂は共にポリ乳酸系樹脂である。また好ましくは、第１の繊維がケナフ繊維であり、第２の繊維がレーヨン繊維であり、且つ第１及び第２の熱可塑性樹脂がポリ乳酸である。
【００１８】
ポリ乳酸系樹脂は、融点が１７０℃程度であって適度な耐熱性を有すると共に成形性に優れ、更に天然繊維との接着性に優れているので、生分解性プラスチックの中でも特に好ましい。また植物由来のポリ乳酸系樹脂は、非石油系の生分解性プラスチックであると共に製造工程においても石油系の溶剤をほとんど使用せず、従って繊維複合樹脂品の製造、使用、廃棄の段階の全体を考えたときの環境負荷が小さい。
【００１９】
また本発明は、繊維複合樹脂品の製造方法に関する。この方法は、第１の繊維と第１の熱可塑性樹脂とを混合して基体層材料を得ること、第２の繊維と第２の熱可塑性樹脂とを混合して表面層材料を得ること、これら基体層材料と表面層材料とを積層して、複合材料積層体を作ること、この複合材料積層体をコンタクトヒーターで加熱して、第１及び第２の熱可塑性樹脂を溶融させること、並びに加熱された複合材料積層体を冷間プレスで成型することを含む。
【００２０】
本発明のこの方法によれば、コンタクトヒーターへの熱可塑性樹脂の付着を抑制して充分な成型性を達成しつつ、充分な強度及び平滑な表面を有する繊維複合樹脂を、繊維材料と熱可塑性樹脂とから得ることができる。
【００２１】
【発明の実施の形態】
以下本発明を図に示した実施形態に基づいて具体的に説明するが、これらの図は本発明の繊維複合樹脂品の例を示す図であり、本発明はこれらの実施形態に限定されるものではない。
【００２２】
本発明の実施形態について図１を用いて説明する。
【００２３】
図１において、基体層１は、第１の繊維と第１の熱可塑性樹脂とを含み、表面層２は、第２の繊維と第２の熱可塑性樹脂とを含む。第１の繊維と第２の繊維は、異なっていても同じであってもよく、また第１の熱可塑性樹脂と第２の熱可塑性樹脂は、異なっていても同じであってもよい。
【００２４】
第１の繊維及び第２の繊維はそれぞれ、本発明の要件を満たす限り、合成繊維及び天然繊維を包含する任意の繊維材料でよく、特に天然由来繊維、例えば木質系又は草本系のような各種のセルロース系の植物由来繊維を使用することができる。植物由来繊維としては、（ａ）木材パルプ、（ｂ）バガス、麦わら、アシ、パピルス、タケ類等のイネ科植物のパルプ、（ｃ）木綿、（ｄ）ケナフ、ローゼル、麻、亜麻、ラミー、ジュート、ヘンプ等の靭皮繊維、（ｅ）ザイザル麻、マニラ麻等の葉脈繊維、（ｆ）レーヨン等の半合成繊維を挙げることができる。また羊毛などの動物繊維、ガラスなどの合成繊維を用いてもよい。
【００２５】
これらのうちでも、一年草であって熱帯地方及び温帯地方での成長が極めて早く容易に栽培できる草本類に属するケナフから採取される繊維を採用することが、天然資源の有効活用の面、リサイクルの面から好ましい。特にケナフの靭皮にはセルロース分が６０％以上と高い含有率で存在していることから、ケナフ靭皮から採取されるケナフ繊維の利用が好ましい。
【００２６】
第１の熱可塑性樹脂及び第２の熱可塑性樹脂としてはそれぞれ任意の合成樹脂又は天然由来樹脂を使用することができる。天然由来樹脂としては、セルロース系生分解プラスチック及びポリ乳酸系樹脂を挙げることができ、好ましくはポリ乳酸系樹脂を使用する。
【００２７】
本発明の繊維複合樹脂品の製造方法を、図２を用いて説明する。本発明の繊維複合樹脂品の製造方法では、第１の繊維と第１の熱可塑性樹脂とを混合して基体層材料１を得ること、第２の繊維と第２の熱可塑性樹脂とを混合して表面層材料２を得ること、これらの基体層材料１と表面層材料２とを積層して、複合材料積層体１０を作ること、この複合材料積層体を、コンタクトヒーター２０において加熱して、第１及び第２の熱可塑性樹脂を溶融させること、並びに加熱された複合材料積層体１２を冷間プレス２２で成形することによって、繊維複合樹脂品１４を製造する。尚、表面層材料２は、樹脂の一部を予め溶融させて繊維間を結合し、不織布としてから用いることができる。このような不織布を用いる場合には、不織布を予めロール状に巻回しておき、必要な長さを切り出して供給してもよい。
【００２８】
ここで基体層材料のためには、下記のパラメータを使用することができる：
繊維材料と熱可塑性樹脂との重量比： ５０：５０〜８０：２０
目付け： ８００ｇ／ｍ２〜２，５００ｇ／ｍ２
繊維径： １ｍｍ以下、例えば１００μｍ以下
繊維長： ２０ｍｍ〜１００ｍｍ、例えば約５０ｍｍ
繊維材料：
木材パルプ、麻、レーヨン、ケナフ、竹などの開繊されたセルロース系繊維、ガラス繊維、カーボン繊維
熱可塑性樹脂：
ポリ乳酸、セルロース系プラスチック、ポリエチレン、ポリ塩化ビニル
【００２９】
また表面層材料のためには、下記のパラメータを使用することができる：
繊維材料と熱可塑性樹脂との重量比： ６０：４０〜８０：２０
目付け： ５０ｇ／ｍ２〜１５０ｇ／ｍ２
繊維径： １５μｍ〜５０μｍ、例えば３０μｍ
繊維長： ２０ｍｍ〜６０ｍｍ、例えば約５０ｍｍ
繊維材料：
木材パルプ、麻、レーヨン、ケナフ、竹などの開繊されたセルロース系繊維、ガラス繊維、カーボン繊維
熱可塑性樹脂：
ポリ乳酸、セルロース系プラスチック、ポリエチレン、ポリ塩化ビニル
【００３０】
これらのパラメータを使用して繊維複合樹脂のボードを製造する場合、本発明の繊維複合樹脂ボードは見かけ密度が０．２ｇ／ｃｍ３以上であるように成型することができる。見かけ密度を０．２ｇ／ｃｍ３以上にすることにより、自動車内装材用途、建築材料用途で使用するために必要な曲げ強さを具備することができる。また、これら用途において良好な曲げ強さを得るためには、見かけ密度は０．４ｇ／ｃｍ３以上、更に好ましくは０．６ｇ／ｃｍ３以上にすることができる。尚、見かけ密度の測定方法は以下の方法で実施したものである。
見かけ密度〔ｇ／ｃｍ３〕＝（繊維複合樹脂ボードの重量〔ｇ〕）／（繊維複合樹脂ボードの体積〔ｃｍ３〕）
【００３１】
ここで、繊維複合樹脂ボードの重量〔ｇ〕は２０℃、６５％ＲＨの標準状態で２４時間放置後の重量とする。一方、繊維複合樹脂ボードの体積〔ｃｍ３〕は、１０ｃｍ×１０ｃｍの試験片の厚みｔ〔ｃｍ〕を荷重をかけない状態で測定し、下式により求めるものとする。
繊維複合樹脂ボードの体積〔ｃｍ３〕＝１０ｃｍ×１０ｃｍ×ｔ〔ｃｍ〕
【００３２】
また、繊維ボードの製造については特許文献１を参照することができる。
【００３３】
以下に本発明を実施例に基づいて説明するが、本発明はこれらに限定されるものではない。
【００３４】
【実施例】
本発明の繊維複合樹脂品と比較例の繊維複合樹脂品とを製造し、表面の様子及び製造の容易さを比較した。
【００３５】
〔実施例１〕
下記の（１）〜（５）の工程を用いて、本発明の繊維複合樹脂品を製造した：
【００３６】
（１）ポリ乳酸系樹脂を公知の方法で繊維化し、捲縮付与後に切断して繊度６．６デシテックス、長さ５１ｍｍの短繊維を得た。このときのポリ乳酸系樹脂のカルボキシ末端濃度は４０当量／トンであった。ケナフ靭皮繊維を６５ｍｍの長さに切断した。ポリ乳酸繊維とケナフ靭皮を３０：７０の重量比で混綿及び開繊してシート状にし、目付１，６００ｇ／ｍ２の基体層材料を得た。このときのケナフ靭皮の繊維径は約６０〜８０μｍ以下であった。
【００３７】
（２）繊維材料としてケナフ靭皮の代わりに直径約３０μｍのレーヨン繊維を使用したこと、及び目付を１００ｇ／ｍ２としたことを除いて基体層材料の場合と同様にして、表面層材料を得た。
【００３８】
（３）得られた基体層材料と表面層材料とを積層して積層体を得た。
【００３９】
（４）この積層体を、２３０℃のコンタクトヒーターの間に挟んで加熱し、ポリ乳酸系樹脂の繊維を溶融させた。
【００４０】
（５）ポリ乳酸系樹脂の繊維を溶融させた積層体をコンタクトヒーターから取り出し、常温で２．４ＭＰａの圧力を用いて加圧圧縮し、厚さが約３ｍｍの繊維複合樹脂のボードを得た。
【００４１】
〔比較例１〕
実施例１の（１）で得られる基体層材料を、表面層材料なしで、実施例１の（４）及び（５）での様に溶融及び加圧圧縮して繊維複合樹脂のボードを得た。
【００４２】
〔比較例２〕
実施例１の（２）で得られる表面層材料の代わりにポリ乳酸１００％を用いて、目付を１００ｇ／ｍ２としたことを除いて、実施例１と同様にして繊維複合樹脂のボードを得た。
【００４３】
〔結果〕
実施例１、並びに比較例１及び２で得られた繊維複合樹脂ボードの表面の様子を調べた。
【００４４】
実施例１の繊維複合樹脂ボードは、表面の繊維が細かいことによって、ボードにふれたときのチクチクとした感じがなかった。また、このボードの表面にフェルト製の吸音材を敷き、はがしたところ、ボード表面の繊維への吸音材の引っ掛かりがなかった。
【００４５】
比較例１の繊維複合樹脂ボードは、表面に太い繊維が露出しており、樹脂品にふれたときにチクチクとした感じがあった。またこのボードの表面にフェルト製の吸音材を敷き、はがしたところ、ボード表面の繊維への吸音材の引っ掛かりがあった。
【００４６】
比較例２の繊維複合樹脂ボードは、コンタクトヒーターから取り出したときに、溶融した表面層の熱可塑性樹脂がヒーター側に付着して成型不良を起こしていた。従って、樹脂の割合を増加させて繊維の露出を抑えることはできないことが分かった。
【００４７】
【発明の効果】
本発明によれば、充分な強度及び平滑な表面を有する繊維複合樹脂品及びその製造方法を得ることができる。
【図面の簡単な説明】
【図１】
図１は、本発明の繊維複合樹脂品の概略図である。
【図２】
図２は、本発明の繊維複合樹脂品の製造方法を説明する図である。
【符号の説明】
１…複合材料の基体層
２…複合材料の表面層
１０…熱可塑性樹脂成分が溶融する前の複合材料積層体（繊維複合樹脂品）
１２…熱可塑性樹脂成分が溶融した状態の複合材料積層体（繊維複合樹脂品）
１４…冷間プレスによって成形された状態の繊維複合樹脂品
２０…コンタクトヒーター
２２…成型用冷間プレス[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a fiber composite resin product, that is, a product in which a fiber material and a thermoplastic resin are composited. In addition, the present invention particularly relates to a fiber composite resin product in which a natural fiber and a natural resin are compounded.
[0002]
[Prior art]
A conventional fiber composite resin product is obtained by combining a fiber material and a thermosetting resin, and subjecting this to heat and pressure molding in a mold.
[0003]
It is also known to obtain a fiber composite resin product from a combination of a fiber material and a thermoplastic resin. In this case, a fiber composite resin product is obtained by heating a combination of a fiber material and a thermoplastic fiber with a contact heater to dissolve the resin component, and then performing pressure molding in a cold press.
[0004]
These fiber composite resin products are used for housing wall materials, floor materials, underfloor shock absorbing and heat insulating materials, and automotive interior materials such as door trim base materials, inner panels, pillar garnishes, rear packages, ceiling base materials, and shock absorbing materials. It is used as a material and a sound absorbing material.
[0005]
In recent years, as a biodegradable fiber board (fiber composite resin product) for reducing the environmental load at the time of disposal, a fiber board in which natural fibers and a thermoplastic cellulose-based biodegradable plastic are combined has been disclosed (Patent Document 1). 1).
[0006]
However, in the fiber board of
[0007]
[Patent Document 1]
JP 2000-127117 A
[Problems to be solved by the invention]
The present invention provides a fiber composite resin article having both sufficient strength and a smooth surface. In order to solve the problems of the prior art and obtain a fiber composite resin product having a smooth surface, it is conceivable to increase the content of the resin to suppress the fiber exposure. However, when a thermoplastic resin is used, if the proportion of the resin is increased, the resin adheres to a contact heater, a mold of a cold press or the like at the time of molding, and the exposure of the fiber cannot be suppressed. In addition, there is a possibility that molding failure may occur. Thus, the present invention provides a fiber composite resin product that solves the problems of the prior art while avoiding the problems of resin adhesion to a mold or the like and poor molding.
[0009]
[Means for Solving the Problems]
The present invention is directed to a fiber composite resin product which solves the above problems, comprising a base layer of a composite material of a first fiber and a first thermoplastic resin, and a second fiber and a second base layer on the base layer. Is a fiber composite resin product having a surface layer of a composite material with a thermoplastic resin. Here, the maximum fiber diameter of the second fiber is smaller than the maximum fiber diameter of the first fiber, and is, for example, 1/2 or less, particularly 1/10 or less. In one embodiment of the present invention, the first fiber has a fiber diameter of 1 mm or less, and the second fiber has a fiber diameter of 50 μm or less, particularly 15 to 30 μm. In the description of the present specification, the term “fiber composite resin product” refers to a composite material of a fiber material and a resin. The term “fiber diameter” refers to the diameter of a fiber observed under a microscope.
[0010]
According to the fiber composite resin article of the present invention, it is possible to obtain a sufficient strength with relatively coarse fibers of the base layer and obtain a smooth surface with fine fibers of the surface layer while avoiding problems during molding.
[0011]
Further, the fiber composite resin article of the present invention comprises a base layer of a composite material of a first fiber and a first thermoplastic resin, and a composite material of a second fiber and a second thermoplastic resin on the base layer. Is a fiber composite resin product having a surface layer. Here, the first fiber is selected from the group consisting of relatively rigid fibers, for example, glass, kenaf, hemp, bamboo, wood pulp, palm hulls and rush, and the second fiber is relatively soft. Fiber, such as rayon, cotton, wool, straw, polyester, silk, nylon and wool. In one aspect of the invention, the first fibers are kenaf fibers and the second fibers are rayon fibers.
[0012]
According to this fiber composite resin product, it is possible to obtain a sufficient strength by the relatively rigid fibers of the base layer and obtain a smooth surface by the relatively soft fibers of the surface layer, while avoiding problems during molding. .
[0013]
In one aspect of the invention, the first and second thermoplastic resins are the same resin.
[0014]
According to this aspect, the compatibility between the base layer and the surface layer can be improved.
[0015]
In one aspect of the present invention, the first and second fibers are both naturally derived fibers, and the first and second thermoplastic resins are both naturally derived resins. Both the fiber and the resin of the present invention may be a biodegradable material.
[0016]
According to this aspect, there is an advantage that it can be made of a naturally-derived material as a whole, whereby the environmental load can be reduced. Here, “naturally-derived” refers to those derived from plant or animal raw materials and not using petroleum-based substances as main raw materials. In addition, when made of a biodegradable material as a whole, it becomes possible to perform a biodegradation treatment at the time of disposal.
[0017]
In one embodiment of the present invention, the first and second thermoplastic resins are both polylactic acid-based resins. Also preferably, the first fiber is kenaf fiber, the second fiber is rayon fiber, and the first and second thermoplastic resins are polylactic acid.
[0018]
Polylactic acid-based resins are particularly preferable among biodegradable plastics because they have a melting point of about 170 ° C., have appropriate heat resistance, are excellent in moldability, and are excellent in adhesion to natural fibers. In addition, plant-derived polylactic acid-based resin is a non-petroleum-based biodegradable plastic and uses almost no petroleum-based solvents in the manufacturing process. Environmental impact is small when considering
[0019]
The present invention also relates to a method for producing a fiber composite resin article. This method comprises mixing a first fiber and a first thermoplastic resin to obtain a substrate layer material, mixing a second fiber and a second thermoplastic resin to obtain a surface layer material, Laminating the substrate layer material and the surface layer material to form a composite material laminate, heating the composite material laminate with a contact heater to melt the first and second thermoplastic resins, and Forming the heated composite laminate in a cold press.
[0020]
According to this method of the present invention, a fiber composite resin having sufficient strength and a smooth surface is formed while suppressing the adhesion of the thermoplastic resin to the contact heater and achieving a sufficient moldability, by using a fiber material and a thermoplastic resin. It can be obtained from resin.
[0021]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, the present invention will be specifically described based on embodiments shown in the drawings, but these drawings are diagrams showing examples of the fiber composite resin article of the present invention, and the present invention is limited to these embodiments Not something.
[0022]
An embodiment of the present invention will be described with reference to FIG.
[0023]
In FIG. 1, the
[0024]
The first fiber and the second fiber may be any fiber materials including synthetic fibers and natural fibers, respectively, as long as the requirements of the present invention are satisfied. Can be used. Examples of plant-derived fibers include (a) wood pulp, (b) bagasse, pulp of grasses such as straw, reed, papyrus, and bamboo, (c) cotton, (d) kenaf, roselle, hemp, flax, and ramie. , Jute, hemp and the like, (e) leaf vein fiber such as Zyzal hemp and Manila hemp, and (f) semi-synthetic fiber such as rayon. Animal fibers such as wool and synthetic fibers such as glass may be used.
[0025]
Among them, the use of fiber collected from kenaf, which belongs to a herbaceous plant that can be cultivated very quickly and easily in the tropics and temperate regions, which is an annual grass, is important in terms of effective use of natural resources. It is preferable from the viewpoint of recycling. In particular, since kenaf bast has a high cellulose content of 60% or more, it is preferable to use kenaf fibers collected from kenaf bast.
[0026]
As the first thermoplastic resin and the second thermoplastic resin, any synthetic resin or natural resin can be used. Examples of the naturally-derived resin include a cellulose-based biodegradable plastic and a polylactic acid-based resin, and a polylactic acid-based resin is preferably used.
[0027]
The method for producing the fiber composite resin article of the present invention will be described with reference to FIG. In the method for producing a fiber composite resin product according to the present invention, the first fiber and the first thermoplastic resin are mixed to obtain the
[0028]
Here, the following parameters can be used for the substrate layer material:
Weight ratio of fiber material to thermoplastic resin: 50:50 to 80:20
Basis weight: 800 g / m 2 to 2,500 g / m 2
Fiber diameter: 1 mm or less, for example, 100 μm or less Fiber length: 20 mm to 100 mm, for example, about 50 mm
Textile material:
Opened cellulosic fiber such as wood pulp, hemp, rayon, kenaf, bamboo, etc., glass fiber, carbon fiber thermoplastic resin:
Polylactic acid, cellulosic plastic, polyethylene, polyvinyl chloride
Also, for the surface layer material, the following parameters can be used:
Weight ratio of fiber material to thermoplastic resin: 60:40 to 80:20
Weight per unit area: 50 g / m 2 to 150 g / m 2
Fiber diameter: 15 μm to 50 μm, for example, 30 μm
Fiber length: 20 mm to 60 mm, for example, about 50 mm
Textile material:
Opened cellulosic fiber such as wood pulp, hemp, rayon, kenaf, bamboo, etc., glass fiber, carbon fiber thermoplastic resin:
Polylactic acid, cellulosic plastic, polyethylene, polyvinyl chloride
When a fiber composite resin board is manufactured using these parameters, the fiber composite resin board of the present invention can be molded so that the apparent density is 0.2 g / cm 3 or more. By setting the apparent density to 0.2 g / cm 3 or more, it is possible to provide a bending strength necessary for use in automotive interior materials and building materials. Further, in order to obtain good bending strength in these applications, the apparent density can be 0.4 g / cm 3 or more, and more preferably 0.6 g / cm 3 or more. In addition, the measuring method of the apparent density was implemented by the following method.
Apparent density [g / cm 3 ] = (weight of fiber composite resin board [g]) / (volume of fiber composite resin board [cm 3 ])
[0031]
Here, the weight [g] of the fiber composite resin board is the weight after standing for 24 hours at a standard condition of 20 ° C. and 65% RH. On the other hand, the volume [cm 3 ] of the fiber composite resin board is obtained by measuring a thickness t [cm] of a test piece of 10 cm × 10 cm without applying a load, and obtaining it by the following formula.
Volume of fiber composite resin board [cm 3 ] = 10 cm × 10 cm × t [cm]
[0032]
In addition, for production of a fiber board,
[0033]
Hereinafter, the present invention will be described based on examples, but the present invention is not limited thereto.
[0034]
【Example】
The fiber composite resin article of the present invention and the fiber composite resin article of the comparative example were produced, and the appearance of the surface and the ease of production were compared.
[0035]
[Example 1]
The fiber composite resin article of the present invention was manufactured using the following steps (1) to (5):
[0036]
(1) A polylactic acid-based resin was converted into a fiber by a known method, and cut after crimping to obtain a short fiber having a fineness of 6.6 dtex and a length of 51 mm. At this time, the carboxy terminal concentration of the polylactic acid-based resin was 40 equivalents / ton. The kenaf bast fibers were cut to a length of 65 mm. Polylactic acid fiber and kenaf bast were mixed and spread at a weight ratio of 30:70 to form a sheet, and a base layer material having a basis weight of 1,600 g / m 2 was obtained. At this time, the fiber diameter of the kenaf bast was about 60 to 80 μm or less.
[0037]
(2) The surface layer material was prepared in the same manner as the base layer material except that rayon fiber having a diameter of about 30 μm was used instead of kenaf bast as the fiber material, and the basis weight was set to 100 g / m 2. Obtained.
[0038]
(3) The obtained substrate layer material and surface layer material were laminated to obtain a laminate.
[0039]
(4) This laminate was heated by being sandwiched between contact heaters at 230 ° C. to melt the fibers of the polylactic acid-based resin.
[0040]
(5) The laminate in which the fibers of the polylactic acid-based resin were melted was taken out of the contact heater and compressed under normal pressure using a pressure of 2.4 MPa to obtain a fiber composite resin board having a thickness of about 3 mm. .
[0041]
[Comparative Example 1]
The substrate layer material obtained in (1) of Example 1 is melted and compressed under pressure as in (4) and (5) of Example 1 without a surface layer material to obtain a fiber composite resin board. Was.
[0042]
[Comparative Example 2]
A fiber composite resin board was prepared in the same manner as in Example 1 except that 100% of polylactic acid was used instead of the surface layer material obtained in (2) of Example 1 and the basis weight was 100 g / m 2. Obtained.
[0043]
〔result〕
The state of the surface of the fiber composite resin board obtained in Example 1 and Comparative Examples 1 and 2 was examined.
[0044]
The fiber composite resin board of Example 1 did not feel tingling when touching the board due to the fineness of the fiber on the surface. When a sound absorbing material made of felt was laid on the surface of the board and peeled off, the sound absorbing material did not catch on the fibers on the board surface.
[0045]
The fiber composite resin board of Comparative Example 1 had thick fibers exposed on the surface, and had a tingling sensation when touching a resin product. Also, a felt-made sound absorbing material was laid on the surface of the board and peeled off.
[0046]
When the fiber composite resin board of Comparative Example 2 was taken out of the contact heater, the molten thermoplastic resin of the surface layer adhered to the heater side and caused molding failure. Therefore, it was found that the exposure of the fibers could not be suppressed by increasing the proportion of the resin.
[0047]
【The invention's effect】
ADVANTAGE OF THE INVENTION According to this invention, the fiber composite resin article which has sufficient intensity | strength and a smooth surface, and its manufacturing method can be obtained.
[Brief description of the drawings]
FIG.
FIG. 1 is a schematic view of a fiber composite resin product of the present invention.
FIG. 2
FIG. 2 is a diagram illustrating a method for producing a fiber composite resin product of the present invention.
[Explanation of symbols]
DESCRIPTION OF
12: Composite material laminate in which thermoplastic resin component is molten (fiber composite resin product)
14: Fiber
Claims (5)
前記基体層上の、第２の繊維と第２の熱可塑性樹脂との複合材料の表面層、
を有する繊維複合樹脂品であって、前記第２の繊維の最大繊維径が前記第１の繊維の最大繊維径よりも小さいことを特徴とする、繊維複合樹脂品。A base layer of a composite material of a first fiber and a first thermoplastic resin, and a surface layer of a composite material of a second fiber and a second thermoplastic resin on the base layer;
Wherein the maximum fiber diameter of the second fiber is smaller than the maximum fiber diameter of the first fiber.
前記基体層上の、第２の繊維と第２の熱可塑性樹脂との第２の複合材料の表面層、
を有する繊維複合樹脂品であって、前記第１の繊維が、ガラス、ケナフ、麻、竹、木材パルプ、やし殻及びいぐさからなる群より選択され、且つ前記第２の繊維が、レーヨン、木綿、羊毛、麦わら、ポリエステル、絹、ナイロン及びウールからなる群より選択されることを特徴とする、繊維複合樹脂品。A base layer of a composite material of a first fiber and a first thermoplastic resin, and a surface layer of a second composite material of a second fiber and a second thermoplastic resin on the base layer;
Wherein the first fibers are selected from the group consisting of glass, kenaf, hemp, bamboo, wood pulp, palm hulls and igusa, and the second fibers are rayon, A fiber composite resin product, which is selected from the group consisting of cotton, wool, straw, polyester, silk, nylon and wool.
第２の繊維と第２の熱可塑性樹脂とを混合して表面層材料を得ること、
前記基体層材料と前記表面層材料とを積層して、複合材料積層体を作ること、
前記複合材料積層体をコンタクトヒーターで加熱して、前記第１及び第２の熱可塑性樹脂を溶融させること、並びに
前記加熱された複合材料積層体を冷間プレスで成型すること、
を含む、請求項１〜４のいずれかに記載の繊維複合樹脂品の製造方法。Mixing a first fiber and a first thermoplastic resin to obtain a substrate layer material;
Mixing the second fiber and the second thermoplastic resin to obtain a surface layer material;
Laminating the substrate layer material and the surface layer material to form a composite material laminate,
Heating the composite material laminate with a contact heater to melt the first and second thermoplastic resins, and molding the heated composite material laminate with a cold press;
The method for producing a fiber composite resin product according to any one of claims 1 to 4, comprising:
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| JP2007261210A (en) * | 2006-03-29 | 2007-10-11 | Shikibo Ltd | Fiber composite resin moldings |
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