JP2017039219A - Method for manufacturing fiber board - Google Patents

Method for manufacturing fiber board Download PDF

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JP2017039219A
JP2017039219A JP2015160535A JP2015160535A JP2017039219A JP 2017039219 A JP2017039219 A JP 2017039219A JP 2015160535 A JP2015160535 A JP 2015160535A JP 2015160535 A JP2015160535 A JP 2015160535A JP 2017039219 A JP2017039219 A JP 2017039219A
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thermoplastic resin
plate
fiber
base material
substrate
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夕季 八木
Yuki Yagi
夕季 八木
弘典 松原
Hironori Matsubara
弘典 松原
有希 井沢
Yuki Izawa
有希 井沢
佳奈 綱場
Kana Tsunaba
佳奈 綱場
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Toyota Boshoku Corp
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Toyota Boshoku Corp
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Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a fiber board which can make a surface smooth while having material feeling, and is excellent in designability.SOLUTION: A method for manufacturing a fiber board includes: a step of arranging a thermoplastic resin fiber web 30 which is formed from a thermoplastic resin constituting a plate-like base material 10 including a vegetable fiber 10F and a thermoplastic resin, on at least the side of one surface 10M of the plate-like base material 10 so as to cover the plate-like base material 10, and integrally heat-pressing the plate-like base material 10 and the thermoplastic resin fiber web 30.SELECTED DRAWING: Figure 1

Description

本発明は、繊維ボードの製造方法に関する。   The present invention relates to a method for manufacturing a fiber board.

従来、繊維ボードを基材として用いる場合は、該ボードが意匠面に表れることが少なかったが、意匠面にも表れる繊維ボードを製造するにあたり、消費者ニーズに応じてその素材感や質感を表に出し、より人々の視覚に訴えるものを製造しようと様々な試みがなされている。   Conventionally, when a fiber board is used as a base material, the board rarely appears on the design surface. However, when manufacturing a fiber board that also appears on the design surface, the texture and texture of the board are expressed according to consumer needs. Various attempts have been made to produce products that appeal to people's vision.

その一例として、例えば下記特許文献１に記載のものが知られている。具体的には、表面に木目模様を有する繊維ボードの製造方法として、木質繊維にバインダーとしての熱硬化性樹脂を混入して形成したマットの上に、着色した紐状樹脂を複数本塗着する工程と、この着色した紐状樹脂が塗着されたマットをホットプレスする工程を含む木質繊維板（繊維ボード）の製造方法が記載されている。   As an example thereof, for example, one described in Patent Document 1 below is known. Specifically, as a method for producing a fiber board having a wood grain pattern on the surface, a plurality of colored string-like resins are applied onto a mat formed by mixing wood fiber with a thermosetting resin as a binder. A manufacturing method of a wood fiber board (fiber board) including a process and a process of hot pressing a mat coated with this colored string-like resin is described.

特開平１１−３２０５１９号公報JP-A-11-320519

しかしながら、引用文献１に記載の繊維ボードの製造方法によると、繊維ボードの表面における木目模様の質感が顕著に表れるという意匠性に優れる反面、表面コーティングを施さないため表面の平滑性に劣り、また、摩擦抵抗などによる繊維ボードの表面劣化が引き起こされやすいという一面がある。   However, according to the manufacturing method of the fiber board described in Cited Document 1, the texture of the wood grain pattern on the surface of the fiber board is excellent, but the surface smoothness is inferior because the surface coating is not applied. There is one aspect that the fiber board surface is easily deteriorated due to frictional resistance and the like.

そこで、摩擦抵抗等による表面劣化を低減させるべく、表面がコーティングされた繊維ボードの製造方法として、例えば、基材の表面にシート状のＰＰフィルム（ポリプロピレンフィルム）を被覆させ、これら基材とＰＰフィルムとを一体的に加熱プレスすることにより基材の表面に成膜を施す工程を含む製造方法が考えられる。しかしながら、この場合、加熱プレス工程において、加熱され引き伸ばされたＰＰフィルムは流動性に優れたものとは言えず、引き伸ばされる過程でその一部が裂けたり伸びムラが生じることで、完成した繊維ボードの表面にひび割れ・欠肉・白化等が発生し得る。また、基材にシート状のＰＰフィルムを被覆させる場合、仮に基材の表面に欠損なく皮膜を施すことが可能であっても、基材における繊維等の微細な形状に倣うことは難しく、基材の素材感や質感までも覆いがちとなる。   In order to reduce surface degradation due to frictional resistance, etc., as a method for producing a fiberboard coated with a surface, for example, a sheet-like PP film (polypropylene film) is coated on the surface of the substrate, and these substrate and PP A manufacturing method including a step of forming a film on the surface of the substrate by integrally heat-pressing the film is conceivable. However, in this case, the heated and stretched PP film is not excellent in fluidity in the hot press process, and part of the stretched film is torn or uneven in the stretched process. Cracks, undercuts, whitening, etc. may occur on the surface. In addition, when a base material is coated with a sheet-like PP film, even if it is possible to coat the surface of the base material without a defect, it is difficult to follow the fine shape of the fibers and the like on the base material. Even the texture and texture of the material tends to be covered.

また、更に意匠性に富んだ繊維ボードを製造すべく、基材とＰＰフィルムの間に装飾性のある別部材を介在させる場合には、基材が有する凹凸に加え、別部材による更に大きな凹凸が生じることとなるため、ＰＰフィルムのひび割れや欠肉がより生じやすく、完成した繊維ボードの表面における平滑化も困難となり、期待する意匠性を実現することが難しい。   In addition, in order to produce a fiber board with a richer design, in the case where another decorative member is interposed between the base material and the PP film, in addition to the unevenness of the base material, larger unevenness due to the separate member Therefore, the PP film is more likely to be cracked or missing, and it is difficult to smooth the surface of the finished fiber board, and it is difficult to realize the expected design.

本発明は上記のような事情に基づいて完成されたものであって、基材の素材感を出しつつ表面の平滑化を可能とする、意匠性に優れた繊維ボードの製造方法を提供することを目的とする。   The present invention has been completed based on the above circumstances, and provides a method for producing a fiber board excellent in design, which enables smoothing of the surface while providing a material feeling of the substrate. With the goal.

上記課題を解決するために、本発明の繊維ボードの製造方法は、植物性繊維と熱可塑性樹脂とを含む板状基材の少なくとも一面側に、前記板状基材を構成する熱可塑性樹脂からなる熱可塑性樹脂繊維ウェブを、前記板状基材を被覆するように配し、前記板状基材と前記熱可塑性樹脂繊維ウェブとを一体的に加熱プレスする工程を含むことを特徴とする。   In order to solve the above-described problems, the fiber board manufacturing method of the present invention is based on a thermoplastic resin constituting the plate-like substrate on at least one surface side of the plate-like substrate containing plant fibers and a thermoplastic resin. The thermoplastic resin fiber web is arranged so as to cover the plate-like substrate, and the plate-like substrate and the thermoplastic resin fiber web are integrally heated and pressed.

このような繊維ボードの製造方法によると、板状基材の一面を被覆するように配した熱可塑性樹脂繊維ウェブが、加熱プレス工程において溶融し該板状基材の一面に行きわたるため、繊維ボードの完成時に、該ボードにおける表面が熱可塑性樹脂の皮膜によってコーティングされることとなり、意匠性に優れた繊維ボードを製造することが可能となる。またこれにより、完成した繊維ボードの繊維が摩耗する事態を軽減できる。また、板状基材を構成する熱可塑性樹脂は、熱可塑性樹脂繊維ウェブ（熱可塑性樹脂繊維を編み込まず積層して広げた綿状のもの）を構成する熱可塑性樹脂と同じものが用いられているため、基材と繊維ウェブの互いの相性が良く、加熱プレス工程において両部材中の熱可塑性樹脂が均一に溶融することとなり、繊維ボードの仕上がりにおける意匠性が優れたものとなる。また、ほぼ同時に溶融する基材側と繊維ウェブ側との熱可塑性樹脂が接着剤の役割を果たすため、繊維ボードの製造時に、板状基材と熱可塑性樹脂繊維ウェブとの間に別途接着層を設ける必要がない。   According to such a fiber board manufacturing method, the thermoplastic resin fiber web arranged so as to cover one surface of the plate-like substrate is melted in the hot press process and reaches one surface of the plate-like substrate. When the board is completed, the surface of the board is coated with a film of a thermoplastic resin, and it becomes possible to manufacture a fiber board excellent in design. This also reduces the situation where the fibers of the finished fiberboard are worn. Moreover, the thermoplastic resin which comprises a plate-shaped base material is the same as the thermoplastic resin which comprises a thermoplastic resin fiber web (a cotton-like thing spread by laminating without weaving thermoplastic resin fibers). Therefore, the compatibility between the base material and the fiber web is good, and the thermoplastic resin in both members is uniformly melted in the hot pressing process, and the design properties in the finish of the fiber board are excellent. Also, since the thermoplastic resin on the substrate side and the fiber web side that melts almost simultaneously plays the role of an adhesive, a separate adhesive layer is provided between the plate-like substrate and the thermoplastic resin fiber web during the production of the fiber board. There is no need to provide.

また、基材を被覆するように配する熱可塑性樹脂繊維ウェブは、その加熱時に、例えばシート状の熱可塑性樹脂フィルム等を用いる場合に比べ、基材中の空気や、基材と熱可塑性樹脂繊維ウェブの間の空気や、熱可塑性樹脂繊維ウェブ中の空気が抜けやすいものとなり、基材と熱可塑性樹脂繊維ウェブとの間に気泡が生じにくい。また、基材を被覆するように配される熱可塑性樹脂繊維ウェブは、例えばシート状の熱可塑性樹脂フィルム等を用いる場合に比べて、その加熱プレス工程において徐々に溶融するため、基材における繊維の微細な形状に倣いやすく、基材の素材感をより生かした繊維ボードを提供可能となる。   Also, the thermoplastic resin fiber web arranged so as to cover the base material is more heated than the case where a sheet-like thermoplastic resin film or the like is used at the time of heating, and the base material and the thermoplastic resin. Air between the fiber webs and air in the thermoplastic resin fiber web easily escape, and bubbles are hardly generated between the base material and the thermoplastic resin fiber web. Further, the thermoplastic resin fiber web arranged so as to cover the base material is gradually melted in the heating press process as compared with the case where a sheet-like thermoplastic resin film or the like is used. This makes it possible to provide a fiber board that can easily follow the fine shape of the substrate and that makes better use of the texture of the base material.

また、例えばシート状の熱可塑性樹脂フィルム等を用いる場合は、溶融したフィルムが外周方向に引き伸ばされることによって起こる表面のひび割れや、フィルムが引っ張られて裂けてしまうことにより生じる表面の部分欠肉等を引き起こすことがある。しかし、ウェブ状の熱可塑性樹脂繊維を用いる場合、熱可塑性樹脂繊維ウェブは編み込まれていない熱可塑性樹脂繊維を積層したものであるため、加熱プレス時に溶融はするものの引き伸ばされるようなことがなく、ひび割れや部分欠肉のような事態発生を懸念する必要もなく、より意匠性に優れた繊維ボードを製造することができる。   In addition, for example, when using a sheet-like thermoplastic resin film or the like, surface cracks caused by the melted film being stretched in the outer circumferential direction, surface partial thinning caused by the film being pulled and torn, etc. May cause. However, when using a thermoplastic resin fiber in the form of a web, the thermoplastic resin fiber web is a laminate of thermoplastic resin fibers that are not knitted. There is no need to worry about the occurrence of a situation such as cracks or partial thinning, and it is possible to produce a fiber board with better design.

上記繊維ボードの製造方法において、前記板状基材と前記熱可塑性樹脂繊維ウェブとの間に、装飾物を介在させるものとすることができる。   In the manufacturing method of the fiber board, a decorative article may be interposed between the plate-like base material and the thermoplastic resin fiber web.

板状基材と熱可塑性樹脂繊維ウェブとの間に装飾物を介在させる場合、基材上に、基材の繊維自体による凹凸に加え、装飾物に起因して大きな凹凸が生じることとなるが、該基材を被覆するようにウェブ状の熱可塑性樹脂繊維を用いることで、溶融した熱可塑性樹脂が装飾物の形状により追従しやすいものとなる。つまり、例えばシート状のフィルム等を用いる場合は、フィルムが装飾物の表面全面に接着せずフィルムと装飾物の凹凸との間に気泡が発生しやすいが、ウェブ状の熱可塑性樹脂繊維では、徐々に溶融する熱可塑性樹脂が、基材や装飾物の凹凸に倣って隙間にまで流入しやすいため、気泡の発生を抑制することができる。これにより、装飾物を介在させてもその意匠性を保ったまま、該装飾物を封入した繊維ボードを製造することが可能となる。   When a decorative object is interposed between the plate-like base material and the thermoplastic resin fiber web, in addition to the unevenness due to the fiber itself of the base material, large unevenness is caused on the base material due to the decorative object. By using web-like thermoplastic resin fibers so as to cover the base material, the molten thermoplastic resin can easily follow the shape of the decoration. That is, for example, when using a sheet-like film or the like, the film does not adhere to the entire surface of the decorative object, and air bubbles are easily generated between the film and the unevenness of the decorative object. Since the thermoplastic resin that gradually melts easily flows into the gaps following the unevenness of the base material or decoration, the generation of bubbles can be suppressed. As a result, it is possible to manufacture a fiber board in which the decorative object is encapsulated while maintaining its design even when the decorative object is interposed.

また、例えばシート状の熱可塑性樹脂フィルム等を用いる場合は、装飾物が有する凹凸形状までも被覆してしまいがち（つまり凹凸形状に倣わずに被覆してしまいがち）であるが、ウェブ状の熱可塑性樹脂繊維を用いることで、上述したように溶融した熱可塑性樹脂が、基材や装飾物の凹凸に倣って流入しやすいため、封入した装飾物の形状やその素材感を生かした繊維ボードを製造することができる。   For example, when a sheet-like thermoplastic resin film or the like is used, the uneven shape of the decorative object tends to be covered (that is, it is likely to be coated without imitating the uneven shape). By using this thermoplastic resin fiber, the molten thermoplastic resin as described above is easy to flow in following the irregularities of the base material and decoration, so the fiber that takes advantage of the shape of the enclosed decoration and its texture A board can be manufactured.

上記繊維ボードの製造方法において、前記板状基材の少なくとも一部が屈曲するように加熱プレスする工程を含むものとすることができる。   The fiber board manufacturing method may include a step of heat pressing so that at least a part of the plate-like substrate is bent.

このような繊維ボードの製造方法によると、加熱プレス工程において板状基材の一部が屈曲するように加熱プレスされても、該板状基材を被覆するようにウェブ状の熱可塑性樹脂繊維を用いているため、溶融した熱可塑性樹脂が、基材の屈曲形状に倣って基材上に行きわたり、繊維ボードにおける表面をコーティングすることが可能となる。例えばシート状の熱可塑性樹脂フィルム等を用いる場合は、加熱プレス工程においてフィルムが引き伸ばされつつ基材と同時に屈曲されるため、例えば屈曲により生じる角部や凸部において、フィルムが薄化し破れてしまったり、繊維ボードの完成時に固化したフィルムが白化する虞があるが、徐々に溶融し基材の屈曲形状に追従する熱可塑性樹脂繊維ウェブを用いる場合、そのような破損や白化の発生を抑制し、意匠性に優れた繊維ボードを製造することが可能となる。つまり平坦な板状の繊維ボードに限らず、立体的な繊維ボードの製造においても表面をコーティングすることが可能となり、その意匠性を維持することができる。   According to such a method of manufacturing a fiber board, even if the plate-like substrate is heated and pressed so that a part of the plate-like substrate is bent in the heating and pressing step, the web-like thermoplastic resin fiber is coated so as to cover the plate-like substrate. Therefore, the molten thermoplastic resin can follow the bent shape of the base material to reach the base material or coat the surface of the fiber board. For example, when using a sheet-like thermoplastic resin film, etc., the film is bent at the same time as the substrate while being stretched in the hot press process. There is a possibility that the film solidified when the fiber board is completed may whiten, but when using a thermoplastic fiber web that gradually melts and follows the bent shape of the base material, the occurrence of such breakage and whitening is suppressed. It becomes possible to produce a fiber board excellent in design. In other words, not only a flat plate-like fiber board but also a three-dimensional fiber board can be coated with a surface, and the design can be maintained.

本発明によれば、基材の素材感を出しつつ表面の平滑化を可能とする、意匠性に優れた繊維ボードの製造方法を提供することができる。   ADVANTAGE OF THE INVENTION According to this invention, the manufacturing method of the fiber board excellent in the designability which makes the surface smooth while giving the raw material feeling of a base material can be provided.

本発明に係る繊維ボードの製造方法の一実施形態において、加熱プレス工程を行う前に板状基材に対して熱可塑性樹脂繊維ウェブを被覆させる態様を示す斜視図。The perspective view which shows the aspect which coat | covers a thermoplastic resin fiber web with respect to a plate-shaped base material in one Embodiment of the manufacturing method of the fiber board which concerns on this invention before performing a heat press process. 図１に続く加熱プレス工程を示す概略断面図。FIG. 2 is a schematic cross-sectional view showing a heating press process following FIG. 1. 図１および図２に示した製造方法によって完成した繊維ボードを示す斜視図。The perspective view which shows the fiber board completed by the manufacturing method shown in FIG. 1 and FIG. 本発明に係る繊維ボードの製造方法の異なる実施形態について、その要部工程を示す概略断面図。The schematic sectional drawing which shows the principal part process about different embodiment of the manufacturing method of the fiber board which concerns on this invention.

＜実施形態１＞
以下、本発明の一実施形態について図面を参照しつつ説明する。本実施形態では、繊維ボードを加熱プレスにて製造する一例について説明するが、その加熱プレスに先立って、図１に示すように、板状基材１０の意匠面となる上面１０Ｍ（一面側）に対して、板状基材１０を被覆するように熱可塑性樹脂繊維ウェブ３０を配置する。 <Embodiment 1>
Hereinafter, an embodiment of the present invention will be described with reference to the drawings. In the present embodiment, an example in which a fiber board is manufactured by a heat press will be described. Prior to the heat press, as shown in FIG. 1, an upper surface 10M (one surface side) serving as a design surface of the plate-like substrate 10. On the other hand, the thermoplastic resin fiber web 30 is disposed so as to cover the plate-like substrate 10.

本実施形態で用いる板状基材１０は、植物性繊維１０Ｆ（例えばケナフ繊維）と熱可塑性樹脂繊維（例えばポリプロピレン繊維）を混合するように何層にも積層したウェブを、針で繊維同士を圧縮して（ニードルパンチ法）マット状にし、これを更に加熱圧縮することによって溶融した熱可塑性樹脂がバインダーとなり、植物性繊維１０Ｆ同士が固結されるように成形されており、板状をなしている。このように成形された板状基材１０は、熱可塑性樹脂層に植物性繊維１０Ｆが含浸されてなる部材とも言える。なお、植物性繊維１０Ｆには、ケナフ繊維の他、ジュート麻が有する繊維等の植物性繊維を用いても良い。   The plate-like substrate 10 used in the present embodiment is a web in which a plurality of layers are laminated so that vegetable fibers 10F (for example, kenaf fibers) and thermoplastic resin fibers (for example, polypropylene fibers) are mixed, and the fibers are connected with needles. Compressed (needle punch method) to form a mat, and further heat-compressed to form a molten thermoplastic resin that serves as a binder and is formed so that the vegetable fibers 10F are consolidated, forming a plate shape ing. It can be said that the plate-like base material 10 thus molded is a member in which a thermoplastic fiber layer is impregnated with vegetable fibers 10F. In addition, you may use vegetable fibers, such as a fiber which a jute hemp has, besides the kenaf fiber for the vegetable fiber 10F.

一方、熱可塑性樹脂繊維ウェブ３０は、板状基材１０を構成する熱可塑性樹脂によって構成されており、該熱可塑性樹脂の繊維を編み込まず何層にも積層し広げた綿状のもの（ウェブ）であり、その外形は定まっていない。このような多層構造のウェブは、熱可塑性樹脂繊維が編み込まれていない不織布であるため、その加熱時において繊維同士が絡まったり引っ張り合わず徐々に溶融する流動性に富んだものとなる。また本実施形態に係る熱可塑性樹脂繊維ウェブ３０には、加熱され溶融した後、冷却されるとほぼ無色透明になる熱可塑性樹脂を用いているが、冷却された状態において色味を有するものや、透明度を落としたものを用いても良く、製造する繊維ボード１００の意匠性に応じて適宜選択可能である。   On the other hand, the thermoplastic resin fiber web 30 is made of a thermoplastic resin that constitutes the plate-like base material 10, and is a cotton-like one (web that is laminated and spread in layers without knitting the fibers of the thermoplastic resin. ) And the external shape is not fixed. Such a multi-layered web is a non-woven fabric in which thermoplastic resin fibers are not knitted, and therefore has high fluidity in which the fibers gradually melt without being entangled or pulled together during heating. In addition, the thermoplastic resin fiber web 30 according to the present embodiment uses a thermoplastic resin that is heated and melted and then becomes substantially colorless and transparent when cooled, but has a color in the cooled state. Further, those with reduced transparency may be used, and can be appropriately selected according to the design properties of the fiber board 100 to be manufactured.

ここで、板状基材１０と熱可塑性樹脂繊維ウェブ３０に用いる熱可塑性樹脂には、双方に同種のものを用いることを条件として、ポリプロピレンの他、ポリエチレン、エチレン／プロピレン共重合体等のポリオレフィン樹脂、ポリ乳酸、ポリカプロラクトン、ポリブチレンサクシネート等の脂肪族ポリエステル樹脂、ポリエチレンテレフタレート、ポリトリメチレンテレフタレート、ポリブチレンテレフタレート等の芳香族ポリエステル樹脂、ポリスチレン、ＡＳ樹脂、ＡＢＳ樹脂等のポリスチレン樹脂、ポリメチルメタクリレート等のアクリル樹脂、ポリアミド樹脂、ポリカーボネート樹脂、及びポリアセタール樹脂等、各種熱可塑性樹脂から繊維ボード１００の用途に応じて適宜選択可能である。   Here, as the thermoplastic resin used for the plate-like base material 10 and the thermoplastic resin fiber web 30, both polypropylene and polyolefin such as polyethylene and ethylene / propylene copolymer are used on condition that both are the same. Resin, polylactic acid, polycaprolactone, aliphatic polyester resins such as polybutylene succinate, polyethylene terephthalate, polytrimethylene terephthalate, polybutylene terephthalate and other aromatic polyester resins, polystyrene, AS resin, ABS resin and other polystyrene resins, poly Various thermoplastic resins such as acrylic resin such as methyl methacrylate, polyamide resin, polycarbonate resin, and polyacetal resin can be appropriately selected according to the use of the fiber board 100.

このような構成の板状基材１０の上面１０Ｍ（一面側）のほぼ全面に、熱可塑性樹脂繊維ウェブ３０を広げて板状基材１０を被覆するように配した後、図２に示すように、これら板状基材１０と熱可塑性樹脂繊維ウェブ３０をプレス機の下型９１と上型９２の間にセットし、型閉じして一体的に加熱プレスする。この加熱プレス工程では熱可塑性樹脂の融点以上の温度で加熱することにより、熱可塑性樹脂繊維ウェブ３０が溶融し、流動体となった熱可塑性樹脂が板状基材１０の上面１０Ｍに行きわたって全面をコーティングするように覆うこととなる。ここで、熱可塑性樹脂繊維ウェブ３０は、加熱されると徐々に溶融し流動性に優れるため、板状基材１０における植物性繊維１０Ｆの微細な形状に倣いつつ板状基材１０の上面１０Ｍ全面に行きわたる。   As shown in FIG. 2, the thermoplastic resin fiber web 30 is spread over the substantially entire upper surface 10 </ b> M (one surface side) of the plate-like substrate 10 having such a configuration so as to cover the plate-like substrate 10. Then, the plate-like substrate 10 and the thermoplastic resin fiber web 30 are set between the lower die 91 and the upper die 92 of the press machine, and the die is closed and integrally heated and pressed. In this heating press process, the thermoplastic resin fiber web 30 is melted by heating at a temperature equal to or higher than the melting point of the thermoplastic resin, and the thermoplastic resin that has become a fluid reaches the upper surface 10M of the plate-like substrate 10. The entire surface will be covered. Here, since the thermoplastic resin fiber web 30 is gradually melted and excellent in fluidity when heated, the upper surface 10M of the plate-like base material 10 is imitating the fine shape of the vegetable fiber 10F in the plate-like base material 10. Go across the entire surface.

また、熱可塑性樹脂繊維ウェブ３０は、板状基材１０を構成する熱可塑性樹脂と同じもので構成されているため、板状基材１０に含まれる熱可塑性樹脂と熱可塑性樹脂繊維ウェブ３０を構成する熱可塑性樹脂の互いの相性が良く、加熱プレス工程において両部材が均一に溶融する。また、このようにしてほぼ同時に溶融する板状基材１０側の熱可塑性樹脂と熱可塑性樹脂繊維ウェブ３０側の熱可塑性樹脂が、接着剤の役割を果たすため、繊維ボード１００の製造過程で、板状基材１０と熱可塑性樹脂繊維ウェブ３０との間に別途接着層を設ける必要がない。   Moreover, since the thermoplastic resin fiber web 30 is comprised with the same thing as the thermoplastic resin which comprises the plate-shaped base material 10, the thermoplastic resin and the thermoplastic resin fiber web 30 which are contained in the plate-shaped base material 10 are comprised. The thermoplastic resins to be formed are compatible with each other, and both members are uniformly melted in the hot press process. In addition, since the thermoplastic resin on the plate-like base material 10 side and the thermoplastic resin on the thermoplastic resin fiber web 30 side that melt almost simultaneously in this way serve as an adhesive, in the manufacturing process of the fiber board 100, There is no need to provide a separate adhesive layer between the plate-like substrate 10 and the thermoplastic resin fiber web 30.

また、板状基材１０に薄膜を形成するものとして、熱可塑性樹脂繊維ウェブ３０を用いているため、その加熱時において板状基材１０中の空気や、板状基材１０と熱可塑性樹脂繊維ウェブ３０との間の空気や、熱可塑性樹脂繊維ウェブ３０中の空気が、繊維と繊維の間から上方に抜けやすく、後の冷却プレス加工を経て熱可塑性樹脂繊維ウェブ３０が凝固し薄膜状の樹脂膜３３となった場合おいて、板状基材１０と樹脂膜３３の間に気泡が生じにくい。また、溶融状態において流動性に優れる熱可塑性樹脂繊維ウェブ３０は、その性質上、引き伸ばされることがないため、一部が裂けてしまう事態や、伸びムラによって欠肉箇所が生じるような事態も起こりにくく、後の冷却プレス加工を経て繊維ボードとなった状態において、ひび割れ・部分欠肉・白化などが抑制された意匠性に優れたものとなる。   Moreover, since the thermoplastic resin fiber web 30 is used as what forms a thin film in the plate-shaped base material 10, the air in the plate-shaped base material 10 at the time of the heating, the plate-shaped base material 10, and a thermoplastic resin The air between the fiber web 30 and the air in the thermoplastic resin fiber web 30 easily escape upward from between the fibers, and the thermoplastic resin fiber web 30 is solidified through a subsequent cooling press process to form a thin film. In the case where the resin film 33 is formed, bubbles are hardly generated between the plate-like substrate 10 and the resin film 33. Further, since the thermoplastic resin fiber web 30 having excellent fluidity in the melted state is not stretched due to its properties, a situation in which a part of the thermoplastic resin fiber web 30 is torn or a lacking part due to unevenness of elongation occurs. It is difficult, and in a state where it has become a fiber board after subsequent cooling press processing, it has excellent design properties in which cracking, partial thinning, whitening, etc. are suppressed.

加熱プレス加工された後、冷却プレスを行うことで熱可塑性樹脂が凝固し、図３に示すように板状基材１０の表面１０Ｍに樹脂膜３３（熱可塑性樹脂繊維ウェブ３０が皮膜となったもの）が張られたような、表面全面がコーティングされた繊維ボード１００が完成する。このように完成した繊維ボード１００は、板状基材１０に含まれる植物性繊維１０Ｆの素材感や質感を生かしつつ、その表面が平滑化された意匠性に優れたものとなる。また、繊維ボード１００における表面がコーティングされていることで、摩擦抵抗などによる表面劣化も抑制でき、時間の経過とともにその意匠性が劣ってしまう事態を軽減できる。   After the hot pressing process, the thermoplastic resin is solidified by performing a cooling press, and the resin film 33 (thermoplastic resin fiber web 30 becomes a film on the surface 10M of the plate-like substrate 10 as shown in FIG. The fiber board 100 with the entire surface coated, such as the ones) is completed. The finished fiberboard 100 is excellent in design with its surface smoothed while taking advantage of the texture and texture of the vegetable fiber 10F contained in the plate-like substrate 10. In addition, since the surface of the fiber board 100 is coated, surface deterioration due to frictional resistance or the like can be suppressed, and a situation in which the design property is deteriorated with time can be reduced.

＜実施形態２＞
次に、本発明の異なる実施形態として、板状基材１０と熱可塑性樹脂繊維ウェブ３０との間に装飾物５０を介在させたもの、さらには板状基材１０の一部を屈曲させた繊維ボードの製造方法について図４Ａ〜図４Ｃを参照して説明する。この装飾物５０とは、繊維ボード２００となった状態で樹脂膜３３を通して視認されるものであり、繊維ボード２００の模様となりその意匠性向上に寄与するものである。
図４Ａに示すように、板状基材１０の上面１０Ｍに、装飾物５０を配し、その上から熱可塑性樹脂繊維ウェブ３０を上面１０Ｍのほぼ全面に広げ、板状基材１０及び装飾物５０を被覆するように配する。そして図４Ｂに示すように、装飾物５０を介在させた板状基材１０と熱可塑性樹脂繊維ウェブ３０をプレス機の下型９１と上型９２の間にセットし、型閉じして一体的に加熱プレスする。 <Embodiment 2>
Next, as a different embodiment of the present invention, a decorative object 50 is interposed between the plate-like substrate 10 and the thermoplastic resin fiber web 30, and a part of the plate-like substrate 10 is bent. The manufacturing method of a fiber board is demonstrated with reference to FIG. 4A-FIG. 4C. The decorative object 50 is visually recognized through the resin film 33 in a state where the fiber board 200 is formed, and becomes a pattern of the fiber board 200 and contributes to an improvement in design.
As shown in FIG. 4A, a decorative object 50 is arranged on the upper surface 10M of the plate-like base material 10, and the thermoplastic resin fiber web 30 is spread over almost the entire surface of the upper surface 10M. 50 so as to cover. Then, as shown in FIG. 4B, the plate-like base material 10 and the thermoplastic resin fiber web 30 with the decoration 50 interposed are set between the lower die 91 and the upper die 92 of the press machine, and the die is closed and integrated. Press to heat.

ここで、下型９１には相対的に上型９２方向へ出っ張る凸形状９１Ｂが設けられており、上型９２には相対的に下型９１と反対方向へ凹む凹形状９２Ａが設けられているため、これら下型９１と上型９２の間にセットし一体的に加熱プレスすると、全体的にその中央が盛り上がるように板状基材１０の一部が屈曲することとなる。なお、この上型９１及び下型９２は、図４Ｂに示す形状に限らず、製造を望む繊維ボード２００の完成形状に合わせて適宜変更可能である。   Here, the lower die 91 is provided with a convex shape 91B that protrudes relatively toward the upper die 92, and the upper die 92 is provided with a concave shape 92A that is relatively recessed in the opposite direction to the lower die 91. Therefore, when the sheet is set between the lower mold 91 and the upper mold 92 and integrally heated and pressed, a part of the plate-like base material 10 is bent so that the center of the entire mold rises. The upper mold 91 and the lower mold 92 are not limited to the shape shown in FIG. 4B, and can be appropriately changed according to the completed shape of the fiber board 200 desired to be manufactured.

このように、加熱プレス工程において板状基材１０の一部が屈曲するように加熱プレスを行った場合であっても、板状基材１０を被覆するものとしてウェブ状の熱可塑性樹脂繊維を用いているため、溶融した熱可塑性樹脂が、板状基材１０の屈曲形状に倣って板状基材１０の上面１０Ｍ全体に行きわたり、繊維ボード２００における表面をムラなくコーティングすることが可能となる。例えばシート状の熱可塑性樹脂フィルム等を被覆して用いる場合は、加熱プレス工程においてフィルムが引き伸ばされつつ板状基材１０と同時に屈曲されるため、例えば屈曲により生じる角部３５や凸部において、フィルムが薄化し破れてしまったり、繊維ボード２００の完成時に固化したフィルムが白化する虞があるが、熱可塑性樹脂繊維ウェブ３０を用いることで、そのような破損や白化の発生を抑制することが可能となる。つまり平坦な板状の繊維ボード１００に限らず、立体的な繊維ボード２００の製造においても表面を良好にコーティングすることが可能となる。   Thus, even if it is a case where it heat-presses so that a part of plate-shaped base material 10 may be bent in a heat-press process, a web-like thermoplastic resin fiber is covered as what covers the plate-shaped base material 10. Therefore, the molten thermoplastic resin can reach the entire upper surface 10M of the plate-like substrate 10 following the bent shape of the plate-like substrate 10, and can coat the surface of the fiber board 200 evenly. Become. For example, when covering and using a sheet-like thermoplastic resin film or the like, since the film is bent at the same time as the plate-like substrate 10 while being stretched in the hot press step, for example, at the corner 35 and the convex portion generated by bending, Although the film may be thinned and torn or the film solidified at the completion of the fiber board 200 may be whitened, the use of the thermoplastic resin fiber web 30 can suppress such breakage and whitening. It becomes possible. That is, the surface can be satisfactorily coated not only in the flat plate-like fiber board 100 but also in the manufacture of the three-dimensional fiber board 200.

また、板状基材１０の上面１０Ｍに装飾物５０が配されることで、板状基材１０上に、板状基材１０の繊維自体による凹凸に加え、装飾物５０に起因して大きな凹凸が生じることとなるが、該板状基材１０及び装飾物５０を被覆するようにウェブ状の熱可塑性樹脂繊維を用いることで、例えばシート状の熱可塑性樹脂フィルム等を用いる場合に比べ、溶融し流動体となった熱可塑性樹脂が装飾物５０の形状により追従しやすいものとなる。逆に、例えばシート状のフィルム等を用いる場合、フィルムが加熱されて軟化し、装飾物の凹凸形状に倣おうとはするものの、装飾物５０の表面全面に万遍なく接着することまでは至らず、板状基材１０とフィルムの間に隙間や気泡が生じてしまう。そして中に残留した気泡が繊維ボード２００の完成時に白く目立って、意匠性を損なうことが起こり得る。この点、溶融状態において流動性に優れる熱可塑性樹脂繊維ウェブ３０は、装飾物５０が有する凹凸形状に追従可能なため、凹凸の隙間にも入り込み板状基材１０の上面１０Ｍに行きわたって全面をコーティングするように覆うこととなり、そのような気泡の発生を抑制することができる。   In addition to the irregularities caused by the fibers of the plate-like substrate 10 on the plate-like substrate 10, the ornament 50 is arranged on the upper surface 10 </ b> M of the plate-like substrate 10. Although unevenness will occur, by using web-like thermoplastic resin fibers so as to cover the plate-like substrate 10 and the decorative object 50, for example, compared to the case of using a sheet-like thermoplastic resin film or the like, The thermoplastic resin that has been melted and turned into a fluid body can easily follow the shape of the decorative object 50. Conversely, for example, when a sheet-like film is used, the film is heated and softened, and although it tries to follow the uneven shape of the ornament, it does not reach the entire surface of the ornament 50 evenly. In addition, gaps and bubbles are generated between the plate-like substrate 10 and the film. And the bubble which remained in it may become conspicuous white at the time of completion of the fiber board 200, and designability may be impaired. In this respect, the thermoplastic resin fiber web 30 having excellent fluidity in the molten state can follow the uneven shape of the decorative object 50, so that it enters the uneven space and reaches the upper surface 10 </ b> M of the plate-like substrate 10. Thus, the generation of such bubbles can be suppressed.

また、例えばシート状の熱可塑性樹脂フィルム等を用いる場合、溶融したフィルムが装飾物５０の特に凸箇所において破れやすく、ひび割れや欠肉を引き起こしたり、特に装飾物５０付近で伸びムラが生じやすいが、ウェブ状の熱可塑性樹脂繊維を用いることで、そのような課題も解決可能となる。また、例えばシート状の熱可塑性樹脂フィルム等は、装飾物５０が有する凹凸形状までも被覆してしまいがちであるが、ウェブ状の熱可塑性樹脂繊維を用いることで、上述したように溶融した熱可塑性樹脂が、装飾物５０の凹凸形状に倣って流入するため、封入した装飾物５０の形状や素材感を生かして視覚に訴えるような繊維ボード２００を製造することが可能となる。   Further, for example, when a sheet-like thermoplastic resin film or the like is used, the melted film is likely to be broken particularly at the convex portion of the decorative object 50, causing cracks or lacking of the thickness, or elongation unevenness is particularly likely to occur near the decorative object 50. Such a problem can be solved by using a web-like thermoplastic resin fiber. Further, for example, a sheet-like thermoplastic resin film or the like tends to cover even the uneven shape of the decorative object 50, but by using web-like thermoplastic resin fibers, the molten heat as described above is used. Since the plastic resin flows in in accordance with the uneven shape of the decorative object 50, it is possible to manufacture the fiber board 200 that appeals to the eye using the shape and texture of the enclosed decorative object 50.

加熱プレス加工された後、冷却プレスを行うことで熱可塑性樹脂が凝固し、図４Ｃに示すように板状基材１０の上面１０Ｍが樹脂膜３３によってコーティングされつつ、板状基材１０と該樹脂膜３３の間には装飾物５０が封入され、更に板状基材１０が部分的に屈曲した繊維ボード２００が完成する。このように完成した繊維ボード２００は、板状基材１０に含まれる植物性繊維１０Ｆ及び装飾物５０の素材感や質感を生かしつつ、その表面が平滑化された意匠性に優れたものとなる。   After the hot pressing process, the thermoplastic resin is solidified by performing a cooling press, and the upper surface 10M of the plate-like substrate 10 is coated with the resin film 33 as shown in FIG. The decoration 50 is enclosed between the resin films 33, and the fiber board 200 in which the plate-like substrate 10 is partially bent is completed. The fiber board 200 thus completed is excellent in design with its surface smoothed while taking advantage of the texture and texture of the plant fiber 10F and the decorative object 50 included in the plate-like substrate 10. .

装飾物５０には、例えば植物葉や金箔などを用いることができ、これを点在するように配しても良いし、一定の模様となるように規則性を持たせて配しても良い。また俸状や紐状のものを縞模様となるように配しても良く、装飾物の素材・形状・配置箇所・配置方法等は、これら例示したものに限らず製造する繊維ボードの意匠性に応じて適宜選択可能である。なお、加熱プレス工程において、その高熱によって変色しにくい装飾物を選択することや、逆に装飾物が変色するのを防ぐように低融点にて加熱プレスを行うことも考慮する。   For example, plant leaves or gold leaf can be used for the decorative object 50, which may be arranged so as to be scattered, or may be arranged with regularity so as to form a certain pattern. . In addition, hooks and strings may be arranged in a striped pattern, and the material, shape, arrangement location, arrangement method, etc. of the decorative object are not limited to those illustrated, but the design properties of the fiberboard to be manufactured It is possible to select appropriately according to. It should be noted that in the hot pressing process, it is also considered to select a decorative object that is not easily discolored by the high heat, and conversely, to perform hot pressing at a low melting point so as to prevent the decorative object from being discolored.

＜他の実施形態＞
本発明は、上記記述及び図面によって説明した実施形態に限定されるものではなく、例えば次のような実施形態も本発明の技術的範囲に含まれ、さらに、下記以外にも要旨を逸脱しない範囲内で種々変更して実施することができる。
（１）上記実施形態１，２では、板状基材１０は、植物性繊維１０Ｆと熱可塑性樹脂を含んで構成されており、加熱圧縮された板状のものを用いているが、単に植物性繊維１０Ｆと熱可塑性樹脂を混合しただけのウェブ状のものでも良いし、ウェブ状のものに熱を加えることなく例えばニードルパンチ法で圧縮しただけのマット状（プレボード状）のものを用いても良い。
（２）上記実施形態２では、板状基材１０と熱可塑性樹脂繊維ウェブ３０との間に装飾物５０を介在させるとともに、板状基材１０の中央が盛り上がるような屈曲形状となるように加熱プレス及び冷却プレスを行っているが、装飾物５０を介在させるだけによる平坦な繊維ボードを製造することとしても良いし、装飾物５０を介在させず、板状基材１０が部分的に屈曲するような立体的な繊維ボードを製造することとしても良い。
（３）本願発明にかかる繊維ボードの製造方法によって製造された繊維ボードは、建築内装材の例えば壁面パネルのアクセントパネルとして用いたり、家具のアクセントパネルとして用いたり、車両用内装材に用いる等、様々な用途が可能である。 <Other embodiments>
The present invention is not limited to the embodiments described with reference to the above description and drawings. For example, the following embodiments are also included in the technical scope of the present invention, and further, the scope not deviating from the gist other than the following. It can be implemented with various changes.
(1) In the first and second embodiments, the plate-like base material 10 is configured to include the vegetable fiber 10F and the thermoplastic resin, and uses a heat-compressed plate-like material. A web-like one in which the synthetic fiber 10F and a thermoplastic resin are mixed may be used, or a mat-like (pre-board-like) member that is simply compressed by the needle punch method without applying heat to the web-like one. Also good.
(2) In the second embodiment, the decorative object 50 is interposed between the plate-like base material 10 and the thermoplastic resin fiber web 30, and the bent shape is formed so that the center of the plate-like base material 10 is raised. Although a heating press and a cooling press are performed, it is also possible to manufacture a flat fiber board by simply interposing the decorative object 50, and the plate-like substrate 10 is partially bent without interposing the decorative object 50. It is good also as manufacturing such a three-dimensional fiber board.
(3) The fiber board manufactured by the manufacturing method of the fiber board according to the invention of the present application is used as an accent panel of a wall panel, for example, an interior panel of a building, an accent panel of furniture, an interior material for a vehicle, etc. Various applications are possible.

１０…板状基材、１０Ｆ…植物性繊維、１０Ｍ…基材１０の上面（一面）、３０…熱可塑性樹脂繊維ウェブ、５０…装飾物、１００…繊維ボード   DESCRIPTION OF SYMBOLS 10 ... Plate-like base material, 10F ... Plant fiber, 10M ... Upper surface (one side) of the base material 10, 30 ... Thermoplastic resin fiber web, 50 ... Decoration, 100 ... Fiber board

Claims (3)

植物性繊維と熱可塑性樹脂とを含む板状基材の少なくとも一面側に、前記板状基材を構成する熱可塑性樹脂からなる熱可塑性樹脂繊維ウェブを、前記板状基材を被覆するように配し、前記板状基材と前記熱可塑性樹脂繊維ウェブとを一体的に加熱プレスする工程を含むことを特徴とする繊維ボードの製造方法。   At least one surface side of a plate-like substrate containing vegetable fibers and a thermoplastic resin is coated with a thermoplastic resin fiber web made of a thermoplastic resin constituting the plate-like substrate so as to cover the plate-like substrate. A method of manufacturing a fiber board, comprising a step of integrally heating and pressing the plate-like base material and the thermoplastic resin fiber web. 前記板状基材と前記熱可塑性樹脂繊維ウェブとの間に、装飾物を介在させることを特徴とする請求項１に記載の繊維ボードの製造方法。   The method for manufacturing a fiber board according to claim 1, wherein a decoration is interposed between the plate-like substrate and the thermoplastic resin fiber web. 前記板状基材の少なくとも一部が屈曲するように加熱プレスする工程を含むことを特徴とする請求項１または請求項２に記載の繊維ボードの製造方法。   The method for manufacturing a fiber board according to claim 1, further comprising a step of heat pressing so that at least a part of the plate-like substrate is bent.
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