JP2024062592A - Substrate, method for manufacturing substrate, and method for manufacturing vehicle interior material - Google Patents

Substrate, method for manufacturing substrate, and method for manufacturing vehicle interior material Download PDF

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JP2024062592A
JP2024062592A JP2022170536A JP2022170536A JP2024062592A JP 2024062592 A JP2024062592 A JP 2024062592A JP 2022170536 A JP2022170536 A JP 2022170536A JP 2022170536 A JP2022170536 A JP 2022170536A JP 2024062592 A JP2024062592 A JP 2024062592A
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fiber
resin layer
layer
fiber resin
substrate
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一夫 前原
信太郎 丸山
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Toyota Boshoku Corp
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/02—Physical, chemical or physicochemical properties
    • B32B7/022—Mechanical properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/08—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer the fibres or filaments of a layer being of different substances, e.g. conjugate fibres, mixture of different fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • B32B2260/023—Two or more layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/14—Mixture of at least two fibres made of different materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/54—Yield strength; Tensile strength

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Dry Formation Of Fiberboard And The Like (AREA)
  • Moulding By Coating Moulds (AREA)
  • Nonwoven Fabrics (AREA)
  • Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
  • Laminated Bodies (AREA)

Abstract

【課題】循環型社会の実現やカーボンニュートラルへの貢献ができる基材、基材の製造方法、及び乗物用内装材の製造方法を提供する。【解決手段】第１繊維樹脂層１１と、第１繊維樹脂層１１上に積層した第２繊維樹脂層１２と、第２繊維樹脂層１２上に積層した第３繊維樹脂層１３と、を備え、第１繊維樹脂層１１及び第３繊維樹脂層１３は、繊維Ａと、熱可塑性樹脂と、を少なくとも含んで構成され、第２繊維樹脂層１２は、繊維Ｂと、繊維Ｂに結着した熱可塑性樹脂と、を少なくとも含んで構成された繊維樹脂体３２の粉砕物４０からなる層状体であって、繊維Ｂが粉砕されたことで、繊維Ａよりも長さが短い繊維Ｃを含む、基材１０。【選択図】図１[Problem] To provide a substrate, a method for manufacturing a substrate, and a method for manufacturing vehicle interior materials that can contribute to the realization of a recycling-oriented society and carbon neutrality. [Solution] A substrate 10 comprising a first fiber resin layer 11, a second fiber resin layer 12 laminated on the first fiber resin layer 11, and a third fiber resin layer 13 laminated on the second fiber resin layer 12, the first fiber resin layer 11 and the third fiber resin layer 13 being composed of at least fiber A and a thermoplastic resin, the second fiber resin layer 12 being a layered body made of pulverized material 40 of a fiber resin body 32 composed of at least fiber B and a thermoplastic resin bonded to fiber B, and the second fiber resin layer 12 being a layered body made of pulverized material 40 of a fiber resin body 32 composed of at least fiber B and a thermoplastic resin bonded to fiber B, and the fiber B has been pulverized to include fiber C that is shorter in length than fiber A. [Selected Figure] Figure 1

Description

本開示は、基材、基材の製造方法、及び乗物用内装材の製造方法に関する。 This disclosure relates to a substrate, a method for manufacturing a substrate, and a method for manufacturing vehicle interior materials.

従来、乗物用内装材の製造方法（車両用内装材の成形方法）として、特許文献１に記載の技術が知られている。具体的に、特許文献１には、ガラス繊維や木質繊維等（以下、単に繊維と呼ぶことがある）にＰＥまたはＰＰ等の熱可塑性樹脂を混入して形成された繊維樹脂部材（内装基材）を、１８０℃～２００℃で、３０～４０秒間加熱し、プレス成形型の下型及び上型間に挿入してプレス成形することが開示されている。 Conventionally, the technology described in Patent Document 1 has been known as a manufacturing method for vehicle interior materials (a molding method for vehicle interior materials). Specifically, Patent Document 1 discloses that a fiber resin member (interior base material) formed by mixing glass fiber, wood fiber, etc. (hereinafter sometimes simply referred to as fiber) with a thermoplastic resin such as PE or PP is heated at 180°C to 200°C for 30 to 40 seconds, and then inserted between the lower and upper dies of a press molding die for press molding.

特開平６－１９０９８２号公報Japanese Patent Application Laid-Open No. 6-190982

昨今では、循環型社会の実現やカーボンニュートラルへの貢献が求められているところ、特許文献１に開示の工程によって製造された内装基材では、繊維に熱可塑性樹脂が結着しているため、この内装基材から反毛等によって繊維を回収して再利用することが難しい。一方、内装基材を粉砕し、その粉砕物を例えば板状に成形して基材として再利用することが考えられるが、内装基材を粉砕すると、繊維の長さが短くなるため、粉砕物からなる基材について強度の低下が懸念される。 In recent years, there has been a demand to contribute to the realization of a recycling-based society and to carbon neutrality, but in the interior base material manufactured by the process disclosed in Patent Document 1, since the thermoplastic resin is bound to the fibers, it is difficult to recover and reuse the fibers from this interior base material by pulverizing or the like. On the other hand, it is possible to crush the interior base material and mold the crushed material into, for example, a plate shape and reuse it as a base material, but when the interior base material is crushed, the length of the fibers becomes shorter, and there is a concern that the strength of the base material made of the crushed material will decrease.

本開示は上記のような事情に基づいて完成された技術であって、循環型社会の実現やカーボンニュートラルへの貢献ができる基材、基材の製造方法、及び乗物用内装材の製造方法を提供することを目的の一つとする。また、強度を向上できる基材、基材の製造方法、及び乗物用内装材の製造方法を提供することを目的の一つとする。 The present disclosure is a technology that has been completed based on the above circumstances, and one of its objectives is to provide a substrate, a method for manufacturing a substrate, and a method for manufacturing a vehicle interior material that can contribute to the realization of a recycling-oriented society and carbon neutrality. Another objective is to provide a substrate, a method for manufacturing a substrate, and a method for manufacturing a vehicle interior material that can improve strength.

本開示は、第１繊維樹脂層と、前記第１繊維樹脂層上に積層した第２繊維樹脂層と、前記第２繊維樹脂層上に積層した第３繊維樹脂層と、を備え、前記第１繊維樹脂層及び前記第３繊維樹脂層は、繊維Ａと、熱可塑性樹脂と、を少なくとも含んで構成され、前記第２繊維樹脂層は、繊維Ｂと、前記繊維Ｂに結着した熱可塑性樹脂と、を少なくとも含んで構成された繊維樹脂体の粉砕物からなる層状体であって、前記繊維Ｂが粉砕されたことで、前記繊維Ａよりも長さが短い繊維Ｃを含む、基材である。 The present disclosure provides a substrate comprising a first fiber resin layer, a second fiber resin layer laminated on the first fiber resin layer, and a third fiber resin layer laminated on the second fiber resin layer, the first fiber resin layer and the third fiber resin layer being composed of at least fiber A and a thermoplastic resin, the second fiber resin layer being a layered body made of a pulverized fiber resin body composed of at least fiber B and a thermoplastic resin bonded to the fiber B, and the fiber B being pulverized to include fiber C having a length shorter than that of the fiber A.

このような基材によると、繊維Ｃを含む第２繊維樹脂層を、繊維Ｃよりも長さが長い繊維Ａを含んだ層である第１繊維樹脂層と第３繊維樹脂層によって挟んだ構成となる。これにより、基材が所定部分を基点として上方や下方に曲げられた場合に、第２繊維樹脂層を挟む第１繊維樹脂層及び第３繊維樹脂層に含まれる比較的強度の高い繊維Ａが、基材の曲がろうとする力に抵抗することができる。よって、第２繊維樹脂層が、繊維樹脂体の粉砕物からなる層状体であり繊維Ａよりも長さが短い繊維Ｃを含んでいたとしても、繊維Ａが有する補強効果を発揮させて強度を向上可能な基材とすることができる。また、第２繊維樹脂層の表裏側（上下側）を、繊維Ａを含んだ層である第１繊維樹脂層及び第３繊維樹脂層によって覆うことで、第２繊維樹脂層が粉砕物からなるものであったとしても、表裏側において繊維Ａの質感を生かした基材とすることができる。さらに、繊維樹脂体として、例えば、乗物用内装材の端材、乗物用内装材の規格外品、リサイクルされた乗物用内装材、カーペットの端材、天井材の端材等の繊維系廃材等（これらを、資材と呼ぶことがある）を採用し、これを粉砕した粉砕物を第２繊維樹脂層として使用することができるので、資材を活用して循環型社会の実現やカーボンニュートラルへの貢献が可能となる。 According to such a substrate, the second fiber resin layer containing fiber C is sandwiched between the first fiber resin layer and the third fiber resin layer, which are layers containing fiber A longer than fiber C. As a result, when the substrate is bent upward or downward from a predetermined portion as a base point, the relatively strong fiber A contained in the first fiber resin layer and the third fiber resin layer sandwiching the second fiber resin layer can resist the force of bending the substrate. Therefore, even if the second fiber resin layer is a layered body made of crushed fiber resin bodies and contains fiber C shorter than fiber A, the fiber A can exert its reinforcing effect to improve the strength of the substrate. In addition, by covering the front and back sides (upper and lower sides) of the second fiber resin layer with the first fiber resin layer and the third fiber resin layer, which are layers containing fiber A, the substrate can be made to take advantage of the texture of fiber A on the front and back sides, even if the second fiber resin layer is made of crushed material. Furthermore, as the fiber-resin body, for example, fiber waste materials such as scraps of vehicle interior materials, non-standard vehicle interior materials, recycled vehicle interior materials, carpet scraps, and ceiling scraps (these are sometimes called materials) can be used, and the crushed material can be used as the second fiber-resin layer, making it possible to utilize materials to contribute to the realization of a recycling-oriented society and carbon neutrality.

上記構成において、前記第２繊維樹脂層は、繊維Ｃ１層と、前記繊維Ｃ１層上に積層した繊維Ｃ２層と、前記繊維Ｃ２層上に積層した繊維Ｃ３層と、を備え、前記繊維Ｃ２層に含まれる繊維Ｃ２は、前記繊維Ｃ１層に含まれる繊維Ｃ１及び前記繊維Ｃ３層に含まれる繊維Ｃ３よりも長さが短くてもよい。 In the above configuration, the second fiber resin layer includes a fiber C1 layer, a fiber C2 layer laminated on the fiber C1 layer, and a fiber C3 layer laminated on the fiber C2 layer, and the fiber C2 contained in the fiber C2 layer may be shorter in length than the fiber C1 contained in the fiber C1 layer and the fiber C3 contained in the fiber C3 layer.

このような基材によると、第２繊維樹脂層において、繊維Ｃ２を含む繊維Ｃ２層を、繊維Ｃ２よりも長さが長い繊維Ｃ１を含んだ繊維Ｃ１層と、繊維Ｃ２よりも長さが長い繊維Ｃ３を含んだ繊維Ｃ３層と、によって挟んだ構成となる。これにより、基材が所定部分を基点として上方や下方に曲げられた場合に、繊維Ｃ２層を挟む繊維Ｃ１層と繊維Ｃ３層に含まれる比較的強度の高い繊維Ｃ（繊維Ｃ１及び繊維Ｃ３）が、基材の曲がろうとする力に抵抗することができるので、強度をより向上可能な基材とすることができる。 In this type of substrate, the second fiber resin layer is configured such that a fiber C2 layer containing fiber C2 is sandwiched between a fiber C1 layer containing fiber C1 longer than fiber C2, and a fiber C3 layer containing fiber C3 longer than fiber C2. As a result, when the substrate is bent upwards or downwards from a predetermined portion as a base point, the relatively strong fibers C (fibers C1 and C3) contained in the fiber C1 layer and fiber C3 layer sandwiching the fiber C2 layer can resist the force that tries to bend the substrate, resulting in a substrate whose strength can be further improved.

また、本開示は、繊維Ａと熱可塑性樹脂とを少なくとも含んで構成される第１繊維樹脂体及び第３繊維樹脂体と、繊維Ｂと前記繊維Ｂに結着した熱可塑性樹脂とを少なくとも含んで構成された第２繊維樹脂体の粉砕物であって、前記繊維Ｂが粉砕されたことで、前記繊維Ａよりも長さが短い繊維Ｃを含む粉砕物と、を準備する準備工程と、前記第１繊維樹脂体を層状にして第１繊維樹脂層を形成し、前記第１繊維樹脂層上に、前記粉砕物を層状に積層して第２繊維樹脂層を形成し、前記第２繊維樹脂層上に、前記第３繊維樹脂体を層状に積層して第３繊維樹脂層を形成する積層工程と、を含む、基材の製造方法である。 The present disclosure also relates to a method for manufacturing a substrate, the method including: a preparation step of preparing a first fiber resin body and a third fiber resin body each including at least fiber A and a thermoplastic resin; and a pulverized product of a second fiber resin body including at least fiber B and a thermoplastic resin bonded to the fiber B, the pulverized product including fiber C having a length shorter than that of the fiber A as a result of the fiber B being pulverized; and a lamination step of layering the first fiber resin body to form a first fiber resin layer, laminating the pulverized product on the first fiber resin layer to form a second fiber resin layer, and laminating the third fiber resin body on the second fiber resin layer to form a third fiber resin layer.

このような基材の製造方法によると、繊維Ｃを含む第２繊維樹脂層を、繊維Ｃよりも長さが長い繊維Ａを含んだ第１繊維樹脂層及び第３繊維樹脂層によって挟んだ構成の基材を得ることができる。このような基材は、所定部分を基点として上方や下方に曲げられた場合に、第１繊維樹脂層及び第３繊維樹脂層に含まれる比較的強度の高い繊維Ａが、基材の曲がろうとする力に抵抗することができる。よって、第２繊維樹脂層が、繊維樹脂体の粉砕物からなる層状体であり繊維Ａよりも長さが短い繊維Ｃを含んでいたとしても、繊維Ａが有する補強効果を発揮させて強度を向上可能な基材を製造することができる。また、第２繊維樹脂層の表裏側（上下側）を、繊維Ａを含んだ第１繊維樹脂層及び第３繊維樹脂層によって覆うように各層を積層させることで、第２繊維樹脂層が粉砕物からなるものであったとしても、表裏面において繊維Ａの質感を生かした基材を得ることができる。さらに、第２繊維樹脂体として、例えば、乗物用内装材の端材、乗物用内装材の規格外品、リサイクルされた乗物用内装材、カーペットの端材、天井材の端材等の繊維系廃材等（これらを、資材と呼ぶことがある）を採用し、これを粉砕した粉砕物を準備して、第２繊維樹脂層として積層させることができるので、資材を活用して循環型社会の実現やカーボンニュートラルへの貢献が可能となる。 According to this method for manufacturing a substrate, a substrate can be obtained in which a second fiber resin layer containing fiber C is sandwiched between a first fiber resin layer and a third fiber resin layer containing fiber A longer than fiber C. When such a substrate is bent upward or downward from a predetermined portion as a base point, the relatively strong fiber A contained in the first fiber resin layer and the third fiber resin layer can resist the force that tries to bend the substrate. Therefore, even if the second fiber resin layer is a layered body made of crushed fiber resin bodies and contains fiber C shorter than fiber A, a substrate can be manufactured that can improve strength by exerting the reinforcing effect of fiber A. In addition, by laminating each layer so that the front and back sides (upper and lower sides) of the second fiber resin layer are covered with the first fiber resin layer and the third fiber resin layer containing fiber A, a substrate that makes use of the texture of fiber A on the front and back sides can be obtained even if the second fiber resin layer is made of crushed material. Furthermore, for the second fiber-resin body, for example, fiber waste materials such as scraps of vehicle interior materials, non-standard vehicle interior materials, recycled vehicle interior materials, carpet scraps, and ceiling scraps (these are sometimes called materials) can be used, and these can be crushed to prepare the crushed material and laminated as the second fiber-resin layer, making it possible to utilize materials to contribute to the realization of a recycling-oriented society and carbon neutrality.

上記製造方法において、前記積層工程では、前記第１繊維樹脂層上において、前記粉砕物を落下させつつその一部を吸い上げて再び落下させることにより、前記繊維Ｃのうち繊維Ｃ１を含んだ繊維Ｃ１層と、前記繊維Ｃのうち前記繊維Ｃ１よりも長さが短い繊維Ｃ２を含み、前記繊維Ｃ１層上に積層した繊維Ｃ２層と、を備えた前記第２繊維樹脂層を、前記第１繊維樹脂層上に形成してもよい。 In the above manufacturing method, in the lamination process, the crushed material may be dropped onto the first fiber resin layer while a portion of the crushed material is sucked up and dropped again, thereby forming the second fiber resin layer on the first fiber resin layer, the second fiber resin layer including a fiber C1 layer including fiber C1 of the fibers C, and a fiber C2 layer including fiber C2 of the fibers C that is shorter than fiber C1 and laminated on the fiber C1 layer.

このような基材の製造方法によると、粉砕物を繊維の長さが異なる繊維体に分けつつ、第１繊維樹脂層上において別々の層として積層させることができる。これにより、強度等の物性を向上可能な基材を効率的に製造することができる。 According to this method for manufacturing a substrate, the crushed material can be separated into fibrous bodies with different fiber lengths and laminated as separate layers on the first fiber resin layer. This makes it possible to efficiently manufacture a substrate that can improve physical properties such as strength.

上記製造方法において、前記積層工程では、前記繊維Ｃのうち前記繊維Ｃ２よりも長さが長い繊維Ｃ３を含み、前記繊維Ｃ２層上に積層した繊維Ｃ３層を備えた前記第２繊維樹脂層を、前記第１繊維樹脂層上に形成してもよい。 In the above manufacturing method, in the lamination process, the second fiber resin layer may be formed on the first fiber resin layer, the second fiber resin layer including fiber C3, which is longer than fiber C2, and is laminated on the fiber C2 layer.

このような基材の製造方法によると、第２繊維樹脂層において、繊維Ｃ２を含む繊維Ｃ２層を、繊維Ｃ２よりも長さが長い繊維Ｃ１を含んだ繊維Ｃ１層と、繊維Ｃ２よりも長さが長い繊維Ｃ３を含んだ繊維Ｃ３層と、によって挟んだ構成の基材を効率的に製造することができる。このような基材は、所定部分を基点として上方や下方に曲げられた場合に、繊維Ｃ２層を挟む繊維Ｃ１層及び繊維Ｃ３層に含まれる比較的強度の高い繊維Ｃ（繊維Ｃ１及び繊維Ｃ３）が、基材の曲がろうとする力に抵抗することができるので、強度をより向上することが可能である。 This method of manufacturing a substrate can efficiently manufacture a substrate in which a fiber C2 layer containing fiber C2 is sandwiched between a fiber C1 layer containing fiber C1 longer than fiber C2 and a fiber C3 layer containing fiber C3 longer than fiber C2 in the second fiber resin layer. When such a substrate is bent upwards or downwards from a predetermined point, the relatively strong fibers C (fibers C1 and C3) contained in the fiber C1 layer and fiber C3 layer sandwiching the fiber C2 layer can resist the force that tries to bend the substrate, so that the strength can be further improved.

上記製造方法は、前記粉砕物をふるいにかけることにより、前記粉砕物を、前記繊維Ｃのうち繊維Ｃ１を含む繊維Ｃ１体と、前記繊維Ｃのうち前記繊維Ｃ１よりも長さが短い繊維Ｃ２を含む繊維Ｃ２体と、に分ける工程を含み、前記積層工程では、前記繊維Ｃ１体を層状にしてなる繊維Ｃ１層と、前記繊維Ｃ１層上に前記繊維Ｃ２体を層状に積層してなる繊維Ｃ２層と、を備えた前記第２繊維樹脂層を、前記第１繊維樹脂層上に形成してもよい。 The manufacturing method includes a step of sieving the pulverized material to separate the pulverized material into a fiber C1 body including fiber C1 of the fibers C and a fiber C2 body including fiber C2 of the fibers C that is shorter in length than fiber C1, and in the layering step, the second fiber resin layer may be formed on the first fiber resin layer, the second fiber resin layer including a fiber C1 layer formed by layering the fiber C1 body and a fiber C2 layer formed by layering the fiber C2 body on the fiber C1 layer.

このような基材の製造方法によると、粉砕物を、繊維の長さが異なる繊維体に分けて、第１繊維樹脂層上において別の層として積層させることができる。これにより、強度等の物性を向上可能な基材を製造することができる。 According to this method for manufacturing a substrate, the crushed material can be separated into fibrous bodies with different fiber lengths and laminated as separate layers on the first fiber resin layer. This makes it possible to manufacture a substrate that can improve physical properties such as strength.

上記製造方法において、前記積層工程では、前記第１繊維樹脂層を搬送部上に形成し、前記第１繊維樹脂層を前記搬送部によって所定方向に搬送し、前記搬送部によって搬送される前記第１繊維樹脂層を、前記搬送部の下方から吸引部によって吸引した状態で、前記第２繊維樹脂層と前記第３繊維樹脂層とを形成してもよい。 In the above manufacturing method, in the lamination process, the first fiber resin layer may be formed on a conveying section, the first fiber resin layer may be conveyed in a predetermined direction by the conveying section, and the second fiber resin layer and the third fiber resin layer may be formed in a state in which the first fiber resin layer conveyed by the conveying section is sucked from below the conveying section by a suction section.

このような基材の製造方法によると、第１繊維樹脂層上に各層を積層させる際に、第１繊維樹脂体、第３繊維樹脂体、又は粉砕物から生じる微細な繊維や塵等が飛散し難い。 According to this method for manufacturing a substrate, when each layer is laminated on the first fiber resin layer, fine fibers and dust generated from the first fiber resin body, the third fiber resin body, or the pulverized material are less likely to scatter.

また、本開示は、上記に記載の工程を行って製造された基材を加熱し、加熱された前記基材を上型と下型との間に挟んでプレスする工程を含む、乗物用内装材の製造方法である。 The present disclosure also provides a method for producing interior materials for vehicles, which includes a step of heating the substrate produced by carrying out the steps described above, and pressing the heated substrate by sandwiching it between an upper mold and a lower mold.

このような工程によると、強度を向上可能な乗物用内装材を製造することができる。また、資材を活用した乗物用内装材を製造することができる。 This process makes it possible to manufacture vehicle interior materials that can improve strength. It also makes it possible to manufacture vehicle interior materials that utilize materials.

本開示によれば、循環型社会の実現やカーボンニュートラルへの貢献ができる基材、基材の製造方法、及び乗物用内装材の製造方法を提供することが可能となる。また、強度を向上できる基材、基材の製造方法、及び乗物用内装材の製造方法を提供することが可能となる。 According to the present disclosure, it is possible to provide a substrate, a method for manufacturing a substrate, and a method for manufacturing a vehicle interior material that can contribute to the realization of a recycling-oriented society and carbon neutrality. It is also possible to provide a substrate, a method for manufacturing a substrate, and a method for manufacturing a vehicle interior material that can improve strength.

実施形態１に係る基材の断面構成を示す図FIG. 1 is a cross-sectional view of a substrate according to a first embodiment; 繊維樹脂体とその粉砕物を示す説明図An explanatory diagram showing a fiber resin body and its pulverized material. 積層工程を示す図A diagram showing the lamination process 第１プレス工程を示す図FIG. 1 shows a first pressing process. 第２プレス工程を示す図FIG. 2 shows the second pressing process. 実施形態２に係る粉砕物を分ける工程を示す図FIG. 10 is a diagram showing a process for separating the pulverized material according to the second embodiment. 積層工程を示す図A diagram showing the lamination process

＜実施形態１＞
本開示の実施形態１を図１から図５によって説明する。本実施形態では、自動車（乗物）のドアに取り付けられるドアトリム（乗物用内装材）１００の前駆体である基材１０、基材１０の製造方法、及びドアトリム１００の製造方法について説明する。 <Embodiment 1>
A first embodiment of the present disclosure will be described with reference to Figures 1 to 5. In this embodiment, a substrate 10 that is a precursor of a door trim (vehicle interior material) 100 that is attached to a door of an automobile (vehicle), a manufacturing method for the substrate 10, and a manufacturing method for the door trim 100 will be described.

図１に示すように、基材１０は、第１繊維樹脂層１１と、第１繊維樹脂層１１上に積層した第２繊維樹脂層１２と、第２繊維樹脂層１２上に積層した第３繊維樹脂層１３と、を備える。第１繊維樹脂層１１及び第３繊維樹脂層１３は、繊維Ａと、熱可塑性樹脂と、を少なくとも含んで構成されている。第１繊維樹脂層１１及び第３繊維樹脂層１３は、第２繊維樹脂層１２よりも弾性率が低く、マット状をなしている。 As shown in FIG. 1, the substrate 10 includes a first fiber resin layer 11, a second fiber resin layer 12 laminated on the first fiber resin layer 11, and a third fiber resin layer 13 laminated on the second fiber resin layer 12. The first fiber resin layer 11 and the third fiber resin layer 13 are composed of at least fiber A and a thermoplastic resin. The first fiber resin layer 11 and the third fiber resin layer 13 have a lower elastic modulus than the second fiber resin layer 12 and are mat-shaped.

繊維Ａとしては、特に限定されないが、例えば、植物性繊維、樹脂繊維、ガラス繊維、金属繊維等のうち１種又は２種以上を採用することができる。植物性繊維としては、ケナフ、亜麻、ヘンプ、ジュート麻、マニラ麻、サイザル麻、雁皮、三椏、楮、バナナ、パイナップル、ココヤシ、トウモロコシ、サトウキビ、バガス、ヤシ、パピルス、葦、エスパルト、サバイグラス、麦、稲、竹、針葉樹（杉、檜等）、広葉樹及び綿花等の植物が有する繊維のうち、１種又は２種以上を採用することができる。繊維Ａの長さは、特に限定されないが、例えば、ＪＩＳ Ｌ１０１５に準拠して算出された平均繊維長が、１０ｍｍ以上でもよく、５０ｍｍ以上でもよく、１００ｍｍ以上でもよい。第１繊維樹脂層１１及び第３繊維樹脂層１３に含まれる熱可塑性樹脂としては、特に限定されないが、ポリオレフィン系樹脂（ポリプロピレン、ポリエチレン等）、ポリエステル系樹脂（ポリ乳酸、ポリカプロラクトン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等の芳香族ポリエステル樹脂）等のうち１種又は２種以上を採用することができる。第１繊維樹脂層１１及び第３繊維樹脂層１３は、同一の繊維Ａ及び熱可塑性樹脂が含まれていてもよく、異なる繊維Ａ又は熱可塑性樹脂が含まれていてもよい。 Fiber A is not particularly limited, but may be one or more of vegetable fibers, resin fibers, glass fibers, metal fibers, etc. As vegetable fibers, one or more of fibers from plants such as kenaf, flax, hemp, jute, Manila hemp, sisal, gampi, mitsumata, paper mulberry, banana, pineapple, coconut, corn, sugarcane, bagasse, palm, papyrus, reed, esparto, sabai grass, wheat, rice, bamboo, coniferous trees (cedar, cypress, etc.), broadleaf trees, and cotton may be used. The length of fiber A is not particularly limited, but may be, for example, an average fiber length calculated in accordance with JIS L1015 of 10 mm or more, 50 mm or more, or 100 mm or more. The thermoplastic resin contained in the first fiber resin layer 11 and the third fiber resin layer 13 is not particularly limited, but one or more of polyolefin resins (polypropylene, polyethylene, etc.), polyester resins (aliphatic polyester resins such as polylactic acid and polycaprolactone, aromatic polyester resins such as polyethylene terephthalate, etc.) can be used. The first fiber resin layer 11 and the third fiber resin layer 13 may contain the same fiber A and thermoplastic resin, or different fiber A or thermoplastic resin.

第２繊維樹脂層１２は、繊維Ｂと、繊維Ｂに結着した熱可塑性樹脂と、を少なくとも含んで構成された繊維樹脂体（第２繊維樹脂体）３２の粉砕物４０（図２参照）からなる層状体であって、繊維Ｂが粉砕されたことで、繊維Ａよりも長さが短い繊維Ｃを含んでいる。繊維Ｂ及び繊維Ｃとしては、特に限定されないが、例えば、植物性繊維、樹脂繊維、ガラス繊維、金属繊維等のうち１種又は２種以上を採用することができる。植物性繊維としては、ケナフ、亜麻、ヘンプ、ジュート麻、マニラ麻、サイザル麻、雁皮、三椏、楮、バナナ、パイナップル、ココヤシ、トウモロコシ、サトウキビ、バガス、ヤシ、パピルス、葦、エスパルト、サバイグラス、麦、稲、竹、針葉樹（杉、檜等）、広葉樹及び綿花等の植物が有する繊維のうち、１種又は２種以上を採用することができる。第２繊維樹脂層１２に含まれる熱可塑性樹脂としては、特に限定されないが、ポリオレフィン系樹脂（ポリプロピレン、ポリエチレン等）、ポリエステル系樹脂（ポリ乳酸、ポリカプロラクトン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等の芳香族ポリエステル樹脂）等のうち１種又は２種以上を採用することができる。 The second fiber resin layer 12 is a layered body made of crushed fiber resin body (second fiber resin body) 32 (see FIG. 2) that is composed of at least fiber B and thermoplastic resin bonded to fiber B, and contains fiber C that is shorter than fiber A due to crushing of fiber B. Fiber B and fiber C are not particularly limited, but one or more of vegetable fibers, resin fibers, glass fibers, metal fibers, etc. can be used. As vegetable fibers, one or more of fibers of plants such as kenaf, flax, hemp, jute, Manila hemp, sisal, gampi, mitsumata, paper mulberry, banana, pineapple, coconut, corn, sugar cane, bagasse, palm, papyrus, reed, esparto, sabai grass, wheat, rice, bamboo, coniferous trees (cedar, cypress, etc.), broad-leaved trees, and cotton can be used. The thermoplastic resin contained in the second fiber resin layer 12 is not particularly limited, but one or more of polyolefin resins (polypropylene, polyethylene, etc.), polyester resins (aliphatic polyester resins such as polylactic acid and polycaprolactone, aromatic polyester resins such as polyethylene terephthalate, etc.) can be used.

繊維Ｂの長さは、特に限定されないが、例えば、ＪＩＳ Ｌ１０１５に準拠して算出された平均繊維長が、１０ｍｍ以上でもよく、５０ｍｍ以上でもよく、１００ｍｍ以上でもよい。繊維Ｃの長さは、繊維Ａの長さ及び繊維Ｂの長さに比して短いものであれば、特に限定されないが、例えば、ＪＩＳ Ｌ１０１５に準拠して算出された平均繊維長が、０．５ｍｍ以上でもよく、１ｍｍ以上でもよく、２ｍｍ以上でもよい。１０ｍｍ未満でもよく、７ｍｍ以下でもよく、５ｍｍ以下でもよい。 The length of fiber B is not particularly limited, but may be, for example, an average fiber length calculated in accordance with JIS L1015 of 10 mm or more, 50 mm or more, or 100 mm or more. The length of fiber C is not particularly limited, so long as it is shorter than the length of fiber A and the length of fiber B, but may be, for example, an average fiber length calculated in accordance with JIS L1015 of 0.5 mm or more, 1 mm or more, or 2 mm or more. It may be less than 10 mm, 7 mm or less, or 5 mm or less.

第２繊維樹脂層１２は、第１繊維樹脂層１１上に積層した繊維Ｃ１層２１と、繊維Ｃ１層２１上に積層した繊維Ｃ２層２２と、繊維Ｃ２層２２上に積層した繊維Ｃ３層２３と、を備える。繊維Ｃ３層２３上には、第３繊維樹脂層１３が積層している。繊維Ｃ１層には、繊維Ｃのうち所定長さの繊維Ｃ１と、繊維Ｃ１に結着した熱可塑性樹脂と、が含まれている。同様に、繊維Ｃ３層には、繊維Ｃのうち所定長さの繊維Ｃ３と、繊維Ｃ３に結着した熱可塑性樹脂と、が含まれている。一方、繊維Ｃ２層には、繊維Ｃのうち、繊維Ｃ１や繊維Ｃ３よりも長さが短い繊維である繊維Ｃ２と、繊維Ｃ２に結着した熱可塑性樹脂と、が含まれている。繊維Ｃ１及び繊維Ｃ３の長さは、繊維Ａの長さ及び繊維Ｂの長さに比して短く、繊維Ｃ２の長さに比して長いものであれば、特に限定されないが、例えば、ＪＩＳ Ｌ１０１５に準拠して算出された平均繊維長が、３ｍｍ以上でもよく、５ｍｍ以上でもよく、１０ｍｍ未満でもよく、７ｍｍ以下でもよい。繊維Ｃ２の長さは、繊維Ａの長さ、繊維Ｂの長さ、繊維Ｃ１の長さ、及び繊維Ｃ３に比して短いものであれば、特に限定されないが、例えば、ＪＩＳ Ｌ１０１５に準拠して算出された平均繊維長が、０．５ｍｍ以上でもよく、１ｍｍ以上でもよく、３ｍｍ未満でもよく、２ｍｍ以下でもよい。 The second fiber resin layer 12 includes a fiber C1 layer 21 laminated on the first fiber resin layer 11, a fiber C2 layer 22 laminated on the fiber C1 layer 21, and a fiber C3 layer 23 laminated on the fiber C2 layer 22. The third fiber resin layer 13 is laminated on the fiber C3 layer 23. The fiber C1 layer includes a fiber C1 of a predetermined length among the fibers C and a thermoplastic resin bonded to the fiber C1. Similarly, the fiber C3 layer includes a fiber C3 of a predetermined length among the fibers C and a thermoplastic resin bonded to the fiber C3. On the other hand, the fiber C2 layer includes a fiber C2 of the fibers C that is shorter than the fibers C1 and C3, and a thermoplastic resin bonded to the fiber C2. The lengths of fibers C1 and C3 are not particularly limited as long as they are shorter than the lengths of fibers A and B and longer than the length of fiber C2, but for example, the average fiber length calculated in accordance with JIS L1015 may be 3 mm or more, 5 mm or more, less than 10 mm, or 7 mm or less. The length of fiber C2 is not particularly limited as long as it is shorter than the lengths of fibers A, B, C1, and C3, but for example, the average fiber length calculated in accordance with JIS L1015 may be 0.5 mm or more, 1 mm or more, less than 3 mm, or 2 mm or less.

続いて、基材１０の製造方法を説明する。図２及び図３に示すように、基材１０の製造方法は、各繊維樹脂体３１，３２，３３や粉砕物４０を準備する準備工程と、各繊維樹脂層１１，１２，１３を積層する積層工程と、を含む。図２に示すように、準備工程は、第２繊維樹脂体３２を粉砕して粉砕物４０を得る粉砕工程を含む。第２繊維樹脂体３２としては、繊維Ｂと、繊維Ｂに結着した熱可塑性樹脂とを含んでいるものであれば、特に限定されないが、例えば、規格外となった基材３２Ｘ、基材の端材３２Ｙ、及びリサイクルにより回収された乗物用内装材３２Ｚ等（資材）のうち、１種又は２種以上を採用することができる。第２繊維樹脂体３２の粉砕方法は、特に限定されず、裁断、引き裂き、叩き割り等の方法を行うことができる。粉砕物４０は、繊維Ｂが粉砕されたことで、繊維Ａ及び繊維Ｂよりも長さが短い繊維Ｃ（図１参照）を含んでいる。尚、本技術で製造された基材１０や、ドアトリム１００を、第２繊維樹脂体３２として再利用することも可能である。 Next, a method for manufacturing the substrate 10 will be described. As shown in FIG. 2 and FIG. 3, the method for manufacturing the substrate 10 includes a preparation step for preparing each fiber resin body 31, 32, 33 and the crushed material 40, and a lamination step for laminating each fiber resin layer 11, 12, 13. As shown in FIG. 2, the preparation step includes a crushing step for crushing the second fiber resin body 32 to obtain the crushed material 40. The second fiber resin body 32 is not particularly limited as long as it contains fiber B and thermoplastic resin bound to fiber B, but for example, one or more of non-standard substrate 32X, substrate scrap material 32Y, and vehicle interior material 32Z (materials) recovered by recycling can be used. The crushing method of the second fiber resin body 32 is not particularly limited, and can be cutting, tearing, smashing, etc. The crushed material 40 contains fiber A and fiber C (see FIG. 1) that is shorter than fiber B due to the crushing of fiber B. Furthermore, the base material 10 and door trim 100 manufactured using this technology can be reused as the second fiber resin body 32.

準備工程は、第１繊維樹脂体３１及び第３繊維樹脂体３３を製造する工程を含む。この製造工程は、特に限定されないが、例えば、繊維Ａと繊維状の熱可塑性樹脂とをカード機によって解繊し積層させた後に、ニードルパンチによって交絡してマット状にすることにより、第１繊維樹脂体３１及び第３繊維樹脂体３３を製造してもよい。 The preparation process includes a process for manufacturing the first fiber resin body 31 and the third fiber resin body 33. This manufacturing process is not particularly limited, but for example, the first fiber resin body 31 and the third fiber resin body 33 may be manufactured by defibrating and stacking the fiber A and the fibrous thermoplastic resin using a carding machine, and then entangling them into a mat shape using a needle punch.

図３に示すように、積層工程では、網状の第１コンベア（搬送部）５１上に、第１繊維樹脂体３１を層状に配して第１繊維樹脂層１１を形成し、第１繊維樹脂層１１上に、粉砕物４０を層状に積層して第２繊維樹脂層１２を形成し、第２繊維樹脂層１２上に、第３繊維樹脂体３３を層状に積層して第３繊維樹脂層１３を形成する。また、積層工程では、 第１繊維樹脂層１１を第１コンベア５１上に形成した後に（又は形成しつつ）、第１繊維樹脂層１１を第１コンベア５１によって下流（所定方向）Ｒに搬送し、第１コンベア５１によって搬送される第１繊維樹脂層１１を、第１コンベア５１の下方から第１吸引部６０によって吸引した状態で、第２繊維樹脂層１２と第３繊維樹脂層１３とを積層させて形成する。第１コンベア５１は、その上面に載置された物体を下流Ｒに搬送する構成とされる。第１吸引部６０は、例えばファンを備え、当該ファンが駆動することにより、第１コンベア５１を通して気体を下方に吸引する構成とされる。 3, in the lamination process, the first fiber resin body 31 is arranged in layers on the mesh-like first conveyor (transport section) 51 to form the first fiber resin layer 11, the crushed material 40 is layered on the first fiber resin layer 11 to form the second fiber resin layer 12, and the third fiber resin body 33 is layered on the second fiber resin layer 12 to form the third fiber resin layer 13. In addition, in the lamination process, after the first fiber resin layer 11 is formed on the first conveyor 51 (or while being formed), the first fiber resin layer 11 is transported downstream (predetermined direction) R by the first conveyor 51, and the second fiber resin layer 12 and the third fiber resin layer 13 are laminated to form the first fiber resin layer 11 and the third fiber resin layer 13 in a state where the first fiber resin layer 11 transported by the first conveyor 51 is sucked by the first suction section 60 from below the first conveyor 51. The first conveyor 51 is configured to transport an object placed on its upper surface downstream R. The first suction section 60 is configured to include, for example, a fan, and when the fan is driven, it draws gas downward through the first conveyor 51.

第１コンベア５１上に、第１繊維樹脂体３１を層状に配して第１繊維樹脂層１１を形成する方法としては、特に限定されず、例えば、図示しない他のコンベアから第１繊維樹脂体３１を第１コンベア５１上に載せ替えるように搬送して第１繊維樹脂層１１を形成してもよく、作業者が第１繊維樹脂体３１を第１コンベア５１上に載置して第１繊維樹脂層１１を形成してもよい。第２繊維樹脂層１２上に、第３繊維樹脂体３３を層状に積層して第３繊維樹脂層１３を形成する方法も、同様とする。 The method of forming the first fiber resin layer 11 by arranging the first fiber resin body 31 in layers on the first conveyor 51 is not particularly limited. For example, the first fiber resin layer 11 may be formed by transferring the first fiber resin body 31 from another conveyor (not shown) onto the first conveyor 51, or an operator may place the first fiber resin body 31 on the first conveyor 51 to form the first fiber resin layer 11. The same applies to the method of forming the third fiber resin layer 13 by stacking the third fiber resin body 33 in layers on the second fiber resin layer 12.

また、積層工程では、第１繊維樹脂層１１上において、粉砕物４０を落下させつつその一部４０Ｙを吸い上げて当該一部４０Ｙを再び吐出部５７から落下させることにより、 繊維Ｃ１を含んだ繊維Ｃ１層２１と、繊維Ｃ２を含み、繊維Ｃ１層２１上に積層した繊維Ｃ２層２２と、繊維Ｃ３を含み、繊維Ｃ２層２２上に積層した繊維Ｃ３層２３と、を備えた第２繊維樹脂層１２を、第１繊維樹脂層１１上に形成する。粉砕物４０は、分離積層装置５０によって、繊維Ｃ１及び繊維Ｃ３を含む第１粉砕物４０Ｘと、繊維Ｃ２を含む第２粉砕物４０Ｙと、に分離された後に、第１繊維樹脂層１１上に、第１粉砕物４０Ｘ、第２粉砕物４０Ｙ、第１粉砕物４０Ｘの順で積層される。尚、本実施形態では、繊維Ｃ１は、繊維Ｃ３と同じ繊維であるとする。 In the lamination process, the pulverized material 40 is dropped onto the first fiber resin layer 11, while a part of the pulverized material 40Y is sucked up and dropped again from the discharge section 57. This forms a second fiber resin layer 12 on the first fiber resin layer 11. The second fiber resin layer 12 includes a fiber C1 layer 21 containing fiber C1, a fiber C2 layer 22 containing fiber C2 and laminated on the fiber C1 layer 21, and a fiber C3 layer 23 containing fiber C3 and laminated on the fiber C2 layer 22. The pulverized material 40 is separated into a first pulverized material 40X containing fiber C1 and fiber C3 and a second pulverized material 40Y containing fiber C2 by the separation and lamination device 50, and then the first pulverized material 40X, the second pulverized material 40Y, and the first pulverized material 40X are laminated on the first fiber resin layer 11 in this order. In this embodiment, the fiber C1 is the same fiber as the fiber C3.

分離積層装置５０は、粉砕物４０を重さで分けることが可能とされる。第２粉砕物４０Ｙは、第１粉砕物４０Ｘよりも軽い。分離積層装置５０は、上面に載置された粉砕物４０を搬送する第２コンベア５２及び第３コンベア５３と、各コンベア５２，５３の下流側端部に配された第２吸引部５４及び第３吸引部５５と、２つの吸引部５４，５５からそれぞれ延びる２つのダクト５８Ａ，５８Ｂが合流する合流部５６と、合流部５６に対しダクト５８Ｃを介して接続された吐出部５７と、を備える。また、分離積層装置５０は、図示しないファンを備え、当該ファンが駆動することにより、２つの吸引部５４，５５から気体と共に第２粉砕物４０Ｙを吸引し、合流部５６を経て吐出部５７に気体と第２粉砕物４０Ｙを送る構成とされる。吐出部５７の吐出口５７Ａは、第２吸引部５４に対し、第１コンベア５１における下流Ｒ側の方向に配されている。第３吸引部５５は、吐出口５７Ａに対し、第１コンベア５１における下流Ｒ側の方向に配されている。第２吸引部５４、吐出部５７の吐出口５７Ａ、及び第３吸引部５５は、この順で第１コンベア５１における下流Ｒ側の方向に向かう位置関係となるように、第１コンベア５１の上方（第１繊維樹脂層１１の上方）に配されている。 The separation and stacking device 50 is capable of separating the crushed material 40 by weight. The second crushed material 40Y is lighter than the first crushed material 40X. The separation and stacking device 50 includes a second conveyor 52 and a third conveyor 53 for transporting the crushed material 40 placed on the upper surface, a second suction section 54 and a third suction section 55 arranged at the downstream end of each conveyor 52, 53, a junction section 56 where two ducts 58A, 58B extending from the two suction sections 54, 55 join, and a discharge section 57 connected to the junction section 56 via a duct 58C. The separation and stacking device 50 also includes a fan (not shown), which is driven to suck in the second crushed material 40Y together with gas from the two suction sections 54, 55, and send the gas and the second crushed material 40Y to the discharge section 57 via the junction section 56. The outlet 57A of the discharge unit 57 is disposed in the direction of the downstream R side of the first conveyor 51 relative to the second suction unit 54. The third suction unit 55 is disposed in the direction of the downstream R side of the first conveyor 51 relative to the outlet 57A. The second suction unit 54, the outlet 57A of the discharge unit 57, and the third suction unit 55 are disposed above the first conveyor 51 (above the first fiber resin layer 11) so that they face in this order toward the downstream R side of the first conveyor 51.

第２コンベア５２は、粉砕物４０を、当該第２コンベア５２についての下流（右方）Ｒに搬送し、第１繊維樹脂層１１上に落下させる。ここで、第２コンベア５２の下流側端部には、第２吸引部５４が配されているので、第２コンベア５２から落下する粉砕物４０は、第２吸引部５４によって気体と共に吸い上げられる第２粉砕物４０Ｙと、第２吸引部５４によって吸い上げられず、そのまま落下する第１粉砕物４０Ｘと、に分離される。そのまま落下した第１粉砕物４０Ｘは、第１繊維樹脂層１１上に層状に積層して繊維Ｃ１層２１を形成する。第２吸引部５４によって吸い上げられた第２粉砕物４０Ｙは、気体と共に合流部５６を経て吐出部５７に送られる。吐出部５７は、第２コンベア５２から第１粉砕物４０Ｘが落下した位置よりも、第１コンベア５１についての下流Ｒ側の方向において、第２粉砕物４０Ｙを吐出口５７Ａから再び落下させ、繊維Ｃ１層２１上に第２粉砕物４０Ｙを層状に積層して繊維Ｃ２層２２を形成する。尚、吐出部５７では、図示しない第４ダクトから気体を外部に排出しつつ、第２粉砕物４０Ｙを吐出口５７Ａから落下させることにより、気体と第２粉砕物４０Ｙとを分離している。 The second conveyor 52 conveys the pulverized material 40 downstream (right) R of the second conveyor 52 and drops it onto the first fiber resin layer 11. Here, since the second suction section 54 is arranged at the downstream end of the second conveyor 52, the pulverized material 40 dropping from the second conveyor 52 is separated into the second pulverized material 40Y that is sucked up together with the gas by the second suction section 54 and the first pulverized material 40X that is not sucked up by the second suction section 54 and falls as it is. The first pulverized material 40X that falls as it is is layered on the first fiber resin layer 11 to form the fiber C1 layer 21. The second pulverized material 40Y sucked up by the second suction section 54 is sent to the discharge section 57 together with the gas via the confluence section 56. The discharge section 57 drops the second pulverized material 40Y again from the discharge port 57A in the direction of the downstream R side of the first conveyor 51 from the position where the first pulverized material 40X dropped from the second conveyor 52, and stacks the second pulverized material 40Y in layers on the fiber C1 layer 21 to form the fiber C2 layer 22. Note that the discharge section 57 separates the gas from the second pulverized material 40Y by dropping the second pulverized material 40Y from the discharge port 57A while discharging the gas to the outside from a fourth duct (not shown).

同様に、第３コンベア５３は、粉砕物４０を、当該第３コンベア５３についての下流（左方）Ｌに搬送し、繊維Ｃ２層２２上に落下させる。ここで、第３コンベア５３の下流側端部には、第３吸引部５５が配されているので、第３コンベア５３から落下する粉砕物４０は、第３吸引部５５によって気体と共に吸い上げられる第２粉砕物４０Ｙと、第３吸引部５５によって吸い上げられず、そのまま落下する第１粉砕物４０Ｘと、に分離される。そのまま落下した第１粉砕物４０Ｘは、繊維Ｃ２層２２上に層状に積層して繊維Ｃ３層２３を形成する。第３吸引部５５によって吸い上げられた第２粉砕物４０Ｙは、気体と共に合流部５６を経て吐出部５７に送られる。吐出部５７は、第３コンベア５３から第１粉砕物４０Ｘが落下した位置よりも、第１コンベア５１についての上流Ｌ側の方向において、第２粉砕物４０Ｙを吐出口５７Ａから再び落下させ、繊維Ｃ１層２１上に第２粉砕物４０Ｙを層状に積層して繊維Ｃ２層２２を形成する。 Similarly, the third conveyor 53 conveys the pulverized material 40 downstream (left) L of the third conveyor 53 and drops it onto the fiber C2 layer 22. Here, since the third suction section 55 is arranged at the downstream end of the third conveyor 53, the pulverized material 40 dropping from the third conveyor 53 is separated into the second pulverized material 40Y sucked up together with the gas by the third suction section 55 and the first pulverized material 40X that is not sucked up by the third suction section 55 and falls as it is. The first pulverized material 40X that falls as it is is layered on the fiber C2 layer 22 to form the fiber C3 layer 23. The second pulverized material 40Y sucked up by the third suction section 55 is sent to the discharge section 57 together with the gas via the confluence section 56. The discharge section 57 drops the second pulverized material 40Y again from the discharge port 57A in the direction of the upstream L side of the first conveyor 51 from the position where the first pulverized material 40X dropped from the third conveyor 53, and stacks the second pulverized material 40Y in layers on the fiber C1 layer 21 to form the fiber C2 layer 22.

以上により、第１繊維樹脂層１１上に、繊維Ｃ１層２１と、繊維Ｃ２層２２と、繊維Ｃ３層２３と、をこの順で積層して、第２繊維樹脂層１２を形成する。第２繊維樹脂層１２上には、第３コンベア５３から第１粉砕物４０Ｘが落下した位置よりも、第１コンベア５１についての下流Ｒ側の方向において、第３繊維樹脂体３３を層状に積層して第３繊維樹脂層１３を形成する。そして、各繊維樹脂層１１，１２，１３が積層してなる積層体１０Ａを、図示しない裁断機によって所定の長さに裁断することにより、図１に示すようなマット体（基材１０）を得る。尚、本実施形態では、便宜上、このマット体を本技術における基材１０として以下説明するが、例えば他の実施形態として、後述する板状体１０Ｂを本技術における基材としてもよい。即ち、本技術における基材には、マット体や板状体を含むものとする。 As described above, the fiber C1 layer 21, the fiber C2 layer 22, and the fiber C3 layer 23 are laminated in this order on the first fiber resin layer 11 to form the second fiber resin layer 12. On the second fiber resin layer 12, the third fiber resin body 33 is laminated in layers in the direction of the downstream R side of the first conveyor 51 from the position where the first pulverized material 40X falls from the third conveyor 53 to form the third fiber resin layer 13. Then, the laminate 10A formed by laminating each fiber resin layer 11, 12, and 13 is cut to a predetermined length by a cutting machine (not shown) to obtain a mat body (substrate 10) as shown in FIG. 1. Note that in this embodiment, for convenience, this mat body will be described below as the substrate 10 in this technology, but in another embodiment, for example, the plate-like body 10B described later may be used as the substrate in this technology. In other words, the substrate in this technology includes a mat body and a plate-like body.

続いて、乗物用内装材の製造方法では、基材１０を加熱した後、図４に示すように、第１成形型７０によってプレスして板状体１０Ｂを形成する第１プレス工程と、図５に示すように、板状体１０Ｂを再度加熱し、第２成形型８０によってプレスしてドアトリム１００を形成する第２プレス工程と、を含む。 The manufacturing method for vehicle interior materials includes a first press process in which the base material 10 is heated and then pressed with a first mold 70 to form a plate-like body 10B as shown in FIG. 4, and a second press process in which the plate-like body 10B is heated again and pressed with a second mold 80 to form a door trim 100 as shown in FIG. 5.

第１プレス工程では、基材１０を、第１繊維樹脂層１１、第２繊維樹脂層１２、及び第３繊維樹脂層１３に含まれる熱可塑性樹脂が溶融可能な温度以上に加熱する。次に、加熱した基材１０を、第１成形型７０の上型７１と下型７２との間に挟んでプレスしてその厚みを薄くした板状にすることで、板状体１０Ｂを形成する。この板状体１０Ｂは、平板状とされるため、例えばその複数をまとめて保管したり運送したりする場合に好適である。 In the first pressing step, the substrate 10 is heated to a temperature equal to or higher than the temperature at which the thermoplastic resin contained in the first fiber resin layer 11, the second fiber resin layer 12, and the third fiber resin layer 13 can melt. Next, the heated substrate 10 is sandwiched between the upper die 71 and the lower die 72 of the first molding die 70 and pressed to reduce its thickness into a plate-like shape, thereby forming a plate-like body 10B. Because this plate-like body 10B is flat, it is suitable, for example, for storing or transporting a plurality of them together.

第２プレス工程では、板状体１０Ｂを、軟化可能な温度以上に加熱する。次に、加熱した板状体１０Ｂを、第２成形型８０の上型８１と下型８２との間に挟んでプレスして、ドアトリム１００を形成する。ドアトリム１００の表裏面が、上型８１の成形面に形成された凹部８１Ａと、下型８２の成形面に形成された凸部８２Ａと、に押圧されることにより、当該ドアトリム１００に角部１００Ａが形成される。尚、第１プレス工程を省略してもよく、その場合、基材１０を加熱した後、第２成形型８０によってプレスすることで、基材１０から直接にドアトリム１００を形成してもよい。 In the second pressing step, the plate-like body 10B is heated to a temperature at which it can be softened or higher. Next, the heated plate-like body 10B is sandwiched between the upper die 81 and the lower die 82 of the second molding die 80 and pressed to form the door trim 100. The front and back surfaces of the door trim 100 are pressed against the recessed portion 81A formed on the molding surface of the upper die 81 and the protruding portion 82A formed on the molding surface of the lower die 82, thereby forming the corner portion 100A in the door trim 100. The first pressing step may be omitted, and in that case, the door trim 100 may be formed directly from the substrate 10 by heating the substrate 10 and then pressing it with the second molding die 80.

続いて、本実施形態の効果について説明する。本実施形態では、第１繊維樹脂層１１と、第１繊維樹脂層１１上に積層した第２繊維樹脂層１２と、第２繊維樹脂層１２上に積層した第３繊維樹脂層１３と、を備え、第１繊維樹脂層１１及び第３繊維樹脂層１３は、繊維Ａと、熱可塑性樹脂と、を少なくとも含んで構成され、第２繊維樹脂層１２は、繊維Ｂと、繊維Ｂに結着した熱可塑性樹脂と、を少なくとも含んで構成された繊維樹脂体３２の粉砕物４０からなる層状体であって、繊維Ｂが粉砕されたことで、繊維Ａよりも長さが短い繊維Ｃを含む、基材１０を示した。 Next, the effects of this embodiment will be described. In this embodiment, a substrate 10 is provided that includes a first fiber resin layer 11, a second fiber resin layer 12 laminated on the first fiber resin layer 11, and a third fiber resin layer 13 laminated on the second fiber resin layer 12, and the first fiber resin layer 11 and the third fiber resin layer 13 are composed of at least fiber A and a thermoplastic resin, and the second fiber resin layer 12 is a layered body made of a pulverized fiber resin body 40 composed of at least fiber B and a thermoplastic resin bonded to fiber B, and includes fiber C that is shorter in length than fiber A due to the pulverization of fiber B.

このような基材１０によると、繊維Ｃを含む第２繊維樹脂層１２を、繊維Ｃよりも長さが長い繊維Ａを含んだ層である第１繊維樹脂層１１と第３繊維樹脂層１３によって挟んだ構成となる。これにより、例えば上記第１プレス工程を経た基材１０（板状体１０Ｂ）が所定部分を基点として上方や下方に曲げられた場合に、第２繊維樹脂層１２を挟む第１繊維樹脂層１１及び第３繊維樹脂層１３に含まれる比較的強度の高い繊維Ａが、基材１０の曲がろうとする力に抵抗することができる。よって、第２繊維樹脂層１２が、繊維樹脂体の粉砕物４０からなる層状体であり繊維Ａよりも長さが短い繊維Ｃを含んでいたとしても、繊維Ａが有する補強効果を発揮させて強度を向上可能な基材１０とすることができる。また、第２繊維樹脂層１２の表裏側（上下側）を、繊維Ａを含んだ層である第１繊維樹脂層１１及び第３繊維樹脂層１３によって覆うことで、第２繊維樹脂層１２が粉砕物４０からなるものであったとしても、表裏側において繊維Ａの質感を生かした基材１０とすることができる。さらに、繊維樹脂体３２として、規格外となった基材３２Ｘ、基材の端材３２Ｙ、及びリサイクルにより回収された乗物用内装材３２Ｚ等（資材）を採用し、これを粉砕した粉砕物４０を第２繊維樹脂層１２として使用することができるので、資材を活用して循環型社会の実現やカーボンニュートラルへの貢献が可能となる。 According to such a substrate 10, the second fiber resin layer 12 containing fiber C is sandwiched between the first fiber resin layer 11 and the third fiber resin layer 13, which are layers containing fiber A longer than fiber C. As a result, for example, when the substrate 10 (plate-shaped body 10B) that has undergone the first pressing process is bent upward or downward from a predetermined portion as a base point, the relatively strong fiber A contained in the first fiber resin layer 11 and the third fiber resin layer 13 that sandwich the second fiber resin layer 12 can resist the force that tries to bend the substrate 10. Therefore, even if the second fiber resin layer 12 is a layered body made of crushed fiber resin body 40 and contains fiber C that is shorter than fiber A, the reinforcing effect of fiber A can be exerted to form a substrate 10 that can improve its strength. In addition, by covering the front and back sides (upper and lower sides) of the second fiber resin layer 12 with the first fiber resin layer 11 and the third fiber resin layer 13, which are layers containing fiber A, the substrate 10 can be made to have the texture of fiber A on the front and back sides even if the second fiber resin layer 12 is made of crushed material 40. Furthermore, non-standard substrates 32X, substrate scraps 32Y, and recycled interior materials 32Z (materials) can be used as the fiber resin body 32, and the crushed material 40 obtained by crushing these can be used as the second fiber resin layer 12, making it possible to utilize materials to contribute to the realization of a recycling-oriented society and carbon neutrality.

第２繊維樹脂層１２は、繊維Ｃ１層２１と、繊維Ｃ１層２１上に積層した繊維Ｃ２層２２と、繊維Ｃ２層２２上に積層した繊維Ｃ３層２３と、を備え、繊維Ｃ２層２２に含まれる繊維Ｃ２は、繊維Ｃ１層２１に含まれる繊維Ｃ１及び繊維Ｃ３層２３に含まれる繊維Ｃ３よりも長さが短い。 The second fiber resin layer 12 comprises a fiber C1 layer 21, a fiber C2 layer 22 laminated on the fiber C1 layer 21, and a fiber C3 layer 23 laminated on the fiber C2 layer 22, and the fiber C2 contained in the fiber C2 layer 22 is shorter in length than the fiber C1 contained in the fiber C1 layer 21 and the fiber C3 contained in the fiber C3 layer 23.

このような基材１０によると、第２繊維樹脂層１２において、繊維Ｃ２を含む繊維Ｃ２層２２を、繊維Ｃ２よりも長さが長い繊維Ｃ１を含んだ繊維Ｃ１層２１と、繊維Ｃ２よりも長さが長い繊維Ｃ３を含んだ繊維Ｃ３層２３と、によって挟んだ構成となる。これにより、基材１０が所定部分を基点として上方や下方に曲げられた場合に、繊維Ｃ２層２２を挟む繊維Ｃ１層２１と繊維Ｃ３層２３に含まれる比較的強度の高い繊維Ｃ（繊維Ｃ１及び繊維Ｃ３）が、基材１０の曲がろうとする力に抵抗することができるので、強度をより向上可能な基材１０とすることができる。 In this substrate 10, the second fiber resin layer 12 has a fiber C2 layer 22 containing fiber C2 sandwiched between a fiber C1 layer 21 containing fiber C1 longer than fiber C2, and a fiber C3 layer 23 containing fiber C3 longer than fiber C2. As a result, when the substrate 10 is bent upward or downward from a predetermined portion as a base point, the relatively strong fibers C (fibers C1 and C3) contained in the fiber C1 layer 21 and fiber C3 layer 23 sandwiching the fiber C2 layer 22 can resist the force that tries to bend the substrate 10, making it possible to make the substrate 10 stronger.

また、本実施形態では、繊維Ａと熱可塑性樹脂とを少なくとも含んで構成される第１繊維樹脂体３１及び第３繊維樹脂体３３と、繊維Ｂと繊維Ｂに結着した熱可塑性樹脂とを少なくとも含んで構成された第２繊維樹脂体３２の粉砕物４０であって、繊維Ｂが粉砕されたことで、繊維Ａよりも長さが短い繊維Ｃを含む粉砕物４０と、を準備する準備工程と、第１繊維樹脂体３１を層状にして第１繊維樹脂層１１を形成し、第１繊維樹脂層１１上に、粉砕物４０を層状に積層して第２繊維樹脂層１２を形成し、第２繊維樹脂層１２上に、第３繊維樹脂体３３を層状に積層して第３繊維樹脂層１３を形成する積層工程と、を含む、基材１０の製造方法を示した。 In the present embodiment, the method for manufacturing the substrate 10 includes a preparation step of preparing the first fiber resin body 31 and the third fiber resin body 33, each of which contains at least fiber A and a thermoplastic resin, and the crushed material 40 of the second fiber resin body 32, each of which contains at least fiber B and a thermoplastic resin bonded to fiber B, and the crushed material 40 contains fiber C, which is shorter than fiber A, due to the crushing of fiber B; and a lamination step of layering the first fiber resin body 31 to form a first fiber resin layer 11, laminating the crushed material 40 on the first fiber resin layer 11 to form a second fiber resin layer 12, and laminating the third fiber resin body 33 on the second fiber resin layer 12 to form a third fiber resin layer 13.

このような基材１０の製造方法によると、繊維Ｃを含む第２繊維樹脂層１２を、繊維Ｃよりも長さが長い繊維Ａを含んだ第１繊維樹脂層１１及び第３繊維樹脂層１３によって挟んだ構成の基材１０を得ることができる。このような基材１０は、所定部分を基点として上方や下方に曲げられた場合に、第１繊維樹脂層１１及び第３繊維樹脂層１３に含まれる比較的強度の高い繊維Ａが、基材１０の曲がろうとする力に抵抗することができる。よって、第２繊維樹脂層１２が、繊維樹脂体の粉砕物４０からなる層状体であり繊維Ａよりも長さが短い繊維Ｃを含んでいたとしても、繊維Ａが有する補強効果を発揮させて強度を向上可能な基材１０を製造することができる。また、第２繊維樹脂層１２の表裏側（上下側）を、繊維Ａを含んだ第１繊維樹脂層１１及び第３繊維樹脂層１３によって覆うように各層を積層させることで、第２繊維樹脂層１２が粉砕物４０からなるものであったとしても、表裏面において繊維Ａの質感を生かした基材１０を得ることができる。さらに、第２繊維樹脂体３２として、資材を採用し、これを粉砕した粉砕物４０を準備して、第２繊維樹脂層１２として積層させることができるので、資材を活用して循環型社会の実現やカーボンニュートラルへの貢献が可能となる。 According to this method for manufacturing the substrate 10, the substrate 10 can be obtained in which the second fiber resin layer 12 containing fiber C is sandwiched between the first fiber resin layer 11 and the third fiber resin layer 13 containing fiber A longer than fiber C. When the substrate 10 is bent upward or downward from a specific portion as a base point, the relatively strong fiber A contained in the first fiber resin layer 11 and the third fiber resin layer 13 can resist the force of bending the substrate 10. Therefore, even if the second fiber resin layer 12 is a layered body made of crushed fiber resin body 40 and contains fiber C shorter than fiber A, the substrate 10 can be manufactured in which the reinforcing effect of fiber A is exerted and the strength can be improved. In addition, by laminating each layer so that the front and back sides (upper and lower sides) of the second fiber resin layer 12 are covered with the first fiber resin layer 11 and the third fiber resin layer 13 containing fiber A, the substrate 10 can be obtained in which the texture of fiber A is utilized on the front and back sides, even if the second fiber resin layer 12 is made of crushed material 40. Furthermore, materials can be used as the second fiber-resin body 32, and the crushed material 40 can be prepared and layered to form the second fiber-resin layer 12, making it possible to utilize materials to contribute to the realization of a recycling-oriented society and carbon neutrality.

積層工程では、第１繊維樹脂層１１上において、粉砕物４０を落下させつつその一部を吸い上げて再び落下させることにより、繊維Ｃのうち繊維Ｃ１を含んだ繊維Ｃ１層２１と、繊維Ｃのうち繊維Ｃ１よりも長さが短い繊維Ｃ２を含み、繊維Ｃ１層２１上に積層した繊維Ｃ２層２２と、を備えた第２繊維樹脂層１２を、第１繊維樹脂層１１上に形成する。 In the lamination process, the pulverized material 40 is dropped onto the first fiber resin layer 11, and part of it is sucked up and dropped again, thereby forming a second fiber resin layer 12 on the first fiber resin layer 11. The second fiber resin layer 12 includes a fiber C1 layer 21 containing fiber C1 of the fibers C, and a fiber C2 layer 22 containing fiber C2 of the fibers C that is shorter than fiber C1 and laminated on the fiber C1 layer 21.

このような基材１０の製造方法によると、粉砕物４０を繊維の長さが異なる繊維体に分けつつ、第１繊維樹脂層１１上において別々の層として積層させることができる。これにより、強度等の物性を向上可能な基材１０を効率的に製造することができる。 According to this method for manufacturing the substrate 10, the pulverized material 40 can be separated into fibrous bodies with different fiber lengths and stacked as separate layers on the first fiber resin layer 11. This makes it possible to efficiently manufacture the substrate 10, which can have improved physical properties such as strength.

積層工程では、繊維Ｃのうち繊維Ｃ２よりも長さが長い繊維Ｃ３を含み、繊維Ｃ２層２２上に積層した繊維Ｃ３層２３を備えた第２繊維樹脂層１２を、第１繊維樹脂層１１上に形成する。 In the lamination process, a second fiber resin layer 12 is formed on the first fiber resin layer 11. The second fiber resin layer 12 includes fiber C3, which is longer than fiber C2, and has a fiber C3 layer 23 laminated on a fiber C2 layer 22.

このような基材１０の製造方法によると、第２繊維樹脂層１２において、繊維Ｃ２を含む繊維Ｃ２層２２を、繊維Ｃ２よりも長さが長い繊維Ｃ１を含んだ繊維Ｃ１層２１と、繊維Ｃ２よりも長さが長い繊維Ｃ３を含んだ繊維Ｃ３層２３と、によって挟んだ構成の基材１０を効率的に製造することができる。このような基材１０は、所定部分を基点として上方や下方に曲げられた場合に、繊維Ｃ２層２２を挟む繊維Ｃ１層２１及び繊維Ｃ３層２３に含まれる比較的強度の高い繊維Ｃ（繊維Ｃ１及び繊維Ｃ３）が、基材１０の曲がろうとする力に抵抗することができるので、強度をより向上することが可能である。 This method of manufacturing the substrate 10 allows efficient manufacturing of a substrate 10 in which the fiber C2 layer 22 containing fiber C2 is sandwiched between a fiber C1 layer 21 containing fiber C1 longer than fiber C2 and a fiber C3 layer 23 containing fiber C3 longer than fiber C2 in the second fiber resin layer 12. When the substrate 10 is bent upward or downward from a predetermined portion as a base point, the relatively strong fibers C (fibers C1 and C3) contained in the fiber C1 layer 21 and fiber C3 layer 23 sandwiching the fiber C2 layer 22 can resist the force that tends to bend the substrate 10, thereby further improving its strength.

積層工程では、第１繊維樹脂層１１を第１コンベア５１上に形成し、第１繊維樹脂層１１を第１コンベア５１によって所定方向に搬送し、第１コンベア５１によって搬送される第１繊維樹脂層１１を、第１コンベア５１の下方から第１吸引部６０によって吸引した状態で、第２繊維樹脂層１２と第３繊維樹脂層１３とを形成する。 In the lamination process, the first fiber resin layer 11 is formed on the first conveyor 51, the first fiber resin layer 11 is transported in a predetermined direction by the first conveyor 51, and the first fiber resin layer 11 transported by the first conveyor 51 is sucked from below the first conveyor 51 by the first suction section 60, and in this state, the second fiber resin layer 12 and the third fiber resin layer 13 are formed.

このような基材１０の製造方法によると、第１繊維樹脂層１１上に各層を積層させる際に、第１繊維樹脂体３１、第３繊維樹脂体３３、又は粉砕物４０から生じる微細な繊維や塵等が飛散し難い。 According to this manufacturing method for the substrate 10, when each layer is laminated on the first fiber resin layer 11, fine fibers, dust, etc. generated from the first fiber resin body 31, the third fiber resin body 33, or the pulverized material 40 are less likely to scatter.

また、本実施形態では、上記に記載の工程を行って製造された基材１０を加熱し、加熱された基材１０を上型８１と下型８２との間に挟んでプレスする工程を含む、ドアトリム１００の製造方法を示した。 In addition, in this embodiment, a method for manufacturing a door trim 100 is shown, which includes a process of heating the base material 10 manufactured by carrying out the process described above, and pressing the heated base material 10 by sandwiching it between an upper die 81 and a lower die 82.

このような工程によると、強度を向上可能なドアトリム１００を製造することができる。また、資材を活用したドアトリム１００を製造することができる。 This process allows the manufacture of a door trim 100 with improved strength. It also allows the manufacture of a door trim 100 that utilizes materials.

＜実施形態２＞
次に、本開示の実施形態２を説明する。本実施形態では、上記実施形態と同じ部位には、同一の符号を用い、構造、製造工程、作用及び効果について重複する説明は省略する。 <Embodiment 2>
Next, a second embodiment of the present disclosure will be described. In this embodiment, the same reference numerals are used for the same parts as in the above embodiment, and redundant descriptions of the structure, manufacturing process, action, and effect will be omitted.

図６に示すように、本実施形態における基材の製造方法は、粉砕物４０をふるい９０にかけることにより、粉砕物４０を、繊維Ｃ１及び繊維Ｃ３を含む第１粉砕物４０Ｘ（繊維Ｃ１体）と、繊維Ｃ２を含む第２粉砕物４０Ｙ（繊維Ｃ２体）と、に分ける工程を含む。ふるい９０は、粉砕物４０を大きさで分けることが可能とされる。第２粉砕物４０Ｙは、第１粉砕物４０Ｘよりもその平均粒子径が小さい。尚、本開示において、「平均粒子径」は、レーザー回折・散乱法によって求めた粒度分布における積算値５０％での粒子径を意味する。 As shown in FIG. 6, the method for manufacturing a substrate in this embodiment includes a step of separating the pulverized material 40 into a first pulverized material 40X (fiber C1 body) containing fiber C1 and fiber C3 and a second pulverized material 40Y (fiber C2 body) containing fiber C2 by passing the pulverized material 40 through a sieve 90. The sieve 90 is capable of separating the pulverized material 40 by size. The second pulverized material 40Y has a smaller average particle diameter than the first pulverized material 40X. In this disclosure, the term "average particle diameter" refers to the particle diameter at an integrated value of 50% in the particle size distribution determined by the laser diffraction/scattering method.

図７に示すように、積層工程では、コンベア２５１によって下流（所定方向）Ｒに搬送される第１繊維樹脂層１１上に、第１粉砕物４０Ｘ、第２粉砕物４０Ｙ、及び第１粉砕物４０Ｘを、この順で積層することにより、第１繊維樹脂層１１上に、第２繊維樹脂層１２を形成する。第１繊維樹脂層１１の上方には、第１粉砕物４０Ｘを吐出する第１吐出部９１と、第１吐出部９１に対して下流側の方向に位置し、第２粉砕物４０Ｙを吐出する第２吐出部９２と、第２吐出部９２に対して下流側の方向に位置し、第１粉砕物４０Ｘを吐出する第３吐出部９３と、が配されている。 As shown in FIG. 7, in the stacking process, the first pulverized material 40X, the second pulverized material 40Y, and the first pulverized material 40X are stacked in this order on the first fiber resin layer 11, which is transported downstream (in a specified direction) R by the conveyor 251, to form a second fiber resin layer 12 on the first fiber resin layer 11. Above the first fiber resin layer 11, there are arranged a first discharge section 91 that discharges the first pulverized material 40X, a second discharge section 92 that is located downstream of the first discharge section 91 and discharges the second pulverized material 40Y, and a third discharge section 93 that is located downstream of the second discharge section 92 and discharges the first pulverized material 40X.

第１繊維樹脂層１１上に、第１吐出部９１から第１粉砕物４０Ｘを吐出することにより、第１粉砕物４０Ｘを層状にしてなる繊維Ｃ１層２１を形成する。繊維Ｃ１層２１上に、第２吐出部９２から第２粉砕物４０Ｙを吐出することにより、第２粉砕物４０Ｙを層状にしてなる繊維Ｃ２層２２を形成する。繊維Ｃ２層２２上に、第３吐出部９３から第１粉砕物４０Ｘを吐出することにより、第１粉砕物４０Ｘを層状にしてなる繊維Ｃ３層２３を形成する。 The first pulverized material 40X is discharged from the first discharge section 91 onto the first fiber resin layer 11 to form a fiber C1 layer 21 made of a layer of the first pulverized material 40X. The second pulverized material 40Y is discharged from the second discharge section 92 onto the fiber C1 layer 21 to form a fiber C2 layer 22 made of a layer of the second pulverized material 40Y. The first pulverized material 40X is discharged from the third discharge section 93 onto the fiber C2 layer 22 to form a fiber C3 layer 23 made of a layer of the first pulverized material 40X.

以上により、第１繊維樹脂層１１上に、繊維Ｃ１層２１と、繊維Ｃ２層２２と、繊維Ｃ３層２３と、をこの順で積層して、第２繊維樹脂層１２を形成する。第２繊維樹脂層１２上には、第３吐出部９３から第１粉砕物４０Ｘを吐出した位置よりも下流側の方向において、第３繊維樹脂体３３を層状に積層して第３繊維樹脂層１３を形成する（図３参照）。そして、各繊維樹脂層１１，１２，１３が積層してなる積層体を、図示しない裁断機によって所定の長さに裁断することにより、基材１０を得る。 As a result, the fiber C1 layer 21, fiber C2 layer 22, and fiber C3 layer 23 are laminated in this order on the first fiber resin layer 11 to form the second fiber resin layer 12. On the second fiber resin layer 12, the third fiber resin body 33 is laminated in layers in a direction downstream of the position where the first pulverized material 40X is discharged from the third discharge section 93 to form the third fiber resin layer 13 (see FIG. 3). The laminate formed by stacking the fiber resin layers 11, 12, and 13 is then cut to a predetermined length by a cutter (not shown) to obtain the substrate 10.

このような基材１０の製造方法によると、粉砕物４０を、繊維の長さが異なる繊維体に分けて、第１繊維樹脂層１１上において別の層として積層させることができる。これにより、強度等の物性を向上可能な基材を製造することができる。 According to this method for manufacturing the substrate 10, the pulverized material 40 can be divided into fibrous bodies with different fiber lengths and laminated as separate layers on the first fiber resin layer 11. This makes it possible to manufacture a substrate that can improve physical properties such as strength.

＜他の実施形態＞
本開示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ず、例えば次のような実施形態も本開示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。 <Other embodiments>
The present disclosure is not limited to the embodiments described above and in the drawings, and for example, the following embodiments are also included within the technical scope of the present disclosure. Furthermore, in addition to the embodiments described below, various modifications can be made without departing from the spirit of the present disclosure.

（１）上記実施形態以外にも、基材の構成は適宜変更可能である。基材において、第２繊維樹脂層を挟む第１繊維樹脂層及び第３繊維樹脂層は、上記実施形態におけるマット状の第１繊維樹脂層及び第３繊維樹脂層よりも弾性率が高い板状体であってもよい。この板状体としては、例えば、上記実施形態におけるマット状の第１繊維樹脂層又は第３繊維樹脂層を加熱した後に、上記第１成形型と同様の成形型でプレス成形したものを採用してもよい。 (1) In addition to the above embodiment, the configuration of the base material can be changed as appropriate. In the base material, the first fiber resin layer and the third fiber resin layer sandwiching the second fiber resin layer may be plate-like bodies having a higher elastic modulus than the mat-like first fiber resin layer and the third fiber resin layer in the above embodiment. For example, this plate-like body may be one obtained by heating the mat-like first fiber resin layer or the mat-like third fiber resin layer in the above embodiment and then press-molding it with a molding die similar to the first molding die.

（２）上記実施形態以外にも、第２繊維樹脂層の構成は適宜変更可能である。上記実施形態では、第２繊維樹脂層は、３層としたが、１層でもよく、２層でもよく、４層以上であってもよい。第２繊維樹脂層が１層である基材を製造する場合は、粉砕物を分離積層装置等によって分離することなく第１繊維樹脂層上にそのまま積層させればよい。第２繊維樹脂層が２層である基材を製造する場合は、上記第３コンベアや第３吸引部を設けなければよい。２繊維樹脂層が４層以上である基材を製造する場合は、その層の数に応じてコンベアや吸引部の数を増やせばよい。 (2) In addition to the above embodiment, the configuration of the second fiber resin layer can be changed as appropriate. In the above embodiment, the second fiber resin layer has three layers, but it may have one layer, two layers, or four or more layers. When manufacturing a substrate having one second fiber resin layer, the crushed material can be directly stacked on the first fiber resin layer without being separated by a separation stacking device or the like. When manufacturing a substrate having two second fiber resin layers, the third conveyor and the third suction section need not be provided. When manufacturing a substrate having four or more second fiber resin layers, the number of conveyors and suction sections can be increased according to the number of layers.

（３）上記実施形態以外にも、粉砕物の前駆体である第２繊維樹脂体は適宜変更可能である。上記実施形態では、第２繊維樹脂体は、規格外となった基材、基材の端材、及びリサイクルにより回収された乗物用内装材としたが、これに限定されない。例えば、第２繊維樹脂体は、カーペットもしくはその端材、又は住宅建材等の繊維含有樹脂部材であってもよい。 (3) In addition to the above embodiment, the second fiber resin body, which is the precursor of the pulverized material, can be changed as appropriate. In the above embodiment, the second fiber resin body is a non-standard base material, a scrap of a base material, and a vehicle interior material recovered by recycling, but is not limited to this. For example, the second fiber resin body may be a fiber-containing resin component such as a carpet or a scrap of the carpet, or a building material for a house.

（４）乗物用内装材としては、車両用に限定されず、種々の乗物において提供されてもよい。例えば、地上の乗物としての列車や遊戯用車両、飛行用乗物としての飛行機やヘリコプター、海上や海中用乗物としての船舶や潜水艇などの乗物についても、本開示の乗物用内装材を適用することができる。 (4) Vehicle interior materials are not limited to use in vehicles, and may be provided for various types of vehicles. For example, the vehicle interior materials disclosed herein can be applied to vehicles such as trains and recreational vehicles as ground vehicles, airplanes and helicopters as flying vehicles, and ships and submarines as marine and underwater vehicles.

１０…基材、１１…第１繊維樹脂層、１２…第２繊維樹脂層、１３…第３繊維樹脂層、２１…繊維Ｃ１層、２２…繊維Ｃ２層、２３…繊維Ｃ３層、３１…第１繊維樹脂体、３２…第２繊維樹脂体、３３…第３繊維樹脂体、４０…粉砕物、５１…第１コンベア（搬送部）、６０…第１吸引部（吸引部）、８１…上型、８２…下型、１００…ドアトリム（乗物用内装材） 10...base material, 11...first fiber resin layer, 12...second fiber resin layer, 13...third fiber resin layer, 21...fiber C1 layer, 22...fiber C2 layer, 23...fiber C3 layer, 31...first fiber resin body, 32...second fiber resin body, 33...third fiber resin body, 40...crushed material, 51...first conveyor (transport section), 60...first suction section (suction section), 81...upper mold, 82...lower mold, 100...door trim (vehicle interior material)

Claims (8)

第１繊維樹脂層と、
前記第１繊維樹脂層上に積層した第２繊維樹脂層と、
前記第２繊維樹脂層上に積層した第３繊維樹脂層と、を備え、
前記第１繊維樹脂層及び前記第３繊維樹脂層は、繊維Ａと、熱可塑性樹脂と、を少なくとも含んで構成され、
前記第２繊維樹脂層は、繊維Ｂと、前記繊維Ｂに結着した熱可塑性樹脂と、を少なくとも含んで構成された繊維樹脂体の粉砕物からなる層状体であって、前記繊維Ｂが粉砕されたことで、前記繊維Ａよりも長さが短い繊維Ｃを含む、基材。 A first fiber resin layer;
a second fiber/resin layer laminated on the first fiber/resin layer;
a third fiber/resin layer laminated on the second fiber/resin layer,
The first fiber resin layer and the third fiber resin layer are configured to contain at least fiber A and a thermoplastic resin,
The second fiber resin layer is a layered body made of a pulverized fiber resin body containing at least fiber B and a thermoplastic resin bonded to the fiber B, and the base material contains fiber C, which is shorter in length than fiber A, as a result of the fiber B being pulverized. 前記第２繊維樹脂層は、
繊維Ｃ１層と、
前記繊維Ｃ１層上に積層した繊維Ｃ２層と、
前記繊維Ｃ２層上に積層した繊維Ｃ３層と、を備え、
前記繊維Ｃ２層に含まれる繊維Ｃ２は、前記繊維Ｃ１層に含まれる繊維Ｃ１及び前記繊維Ｃ３層に含まれる繊維Ｃ３よりも長さが短い、請求項１に記載の基材。 The second fiber resin layer is
A fiber C1 layer;
A fiber C2 layer laminated on the fiber C1 layer;
A fiber C3 layer laminated on the fiber C2 layer,
The substrate according to claim 1 , wherein the fibers C2 contained in the fiber C2 layer are shorter in length than the fibers C1 contained in the fiber C1 layer and the fibers C3 contained in the fiber C3 layer. 繊維Ａと熱可塑性樹脂とを少なくとも含んで構成される第１繊維樹脂体及び第３繊維樹脂体と、
繊維Ｂと前記繊維Ｂに結着した熱可塑性樹脂とを少なくとも含んで構成された第２繊維樹脂体の粉砕物であって、前記繊維Ｂが粉砕されたことで、前記繊維Ａよりも長さが短い繊維Ｃを含む粉砕物と、を準備する準備工程と、
前記第１繊維樹脂体を層状にして第１繊維樹脂層を形成し、
前記第１繊維樹脂層上に、前記粉砕物を層状に積層して第２繊維樹脂層を形成し、
前記第２繊維樹脂層上に、前記第３繊維樹脂体を層状に積層して第３繊維樹脂層を形成する積層工程と、を含む、基材の製造方法。 a first fiber-resin body and a third fiber-resin body each including at least a fiber A and a thermoplastic resin;
a preparation step of preparing a pulverized product of a second fiber resin body including at least fiber B and a thermoplastic resin bonded to the fiber B, the pulverized product including fiber C having a length shorter than that of the fiber A by pulverizing the fiber B;
The first fiber-resin body is layered to form a first fiber-resin layer;
The pulverized material is laminated in layers on the first fiber resin layer to form a second fiber resin layer;
and a lamination step of laminating the third fiber resin body in a layered manner on the second fiber resin layer to form a third fiber resin layer. 前記積層工程では、前記第１繊維樹脂層上において、前記粉砕物を落下させつつその一部を吸い上げて再び落下させることにより、
前記繊維Ｃのうち繊維Ｃ１を含んだ繊維Ｃ１層と、
前記繊維Ｃのうち前記繊維Ｃ１よりも長さが短い繊維Ｃ２を含み、前記繊維Ｃ１層上に積層した繊維Ｃ２層と、を備えた前記第２繊維樹脂層を、前記第１繊維樹脂層上に形成する、請求項３に記載の基材の製造方法。 In the lamination step, the crushed material is dropped onto the first fiber resin layer, and a part of the crushed material is sucked up and dropped again.
A fiber C1 layer containing fiber C1 among the fibers C;
The method for manufacturing a substrate according to claim 3, further comprising forming the second fiber resin layer on the first fiber resin layer, the second fiber resin layer including a fiber C2 layer laminated on the fiber C1 layer, the fiber C2 layer including fibers C2 among the fibers C that are shorter in length than the fibers C1. 前記積層工程では、前記繊維Ｃのうち前記繊維Ｃ２よりも長さが長い繊維Ｃ３を含み、前記繊維Ｃ２層上に積層した繊維Ｃ３層を備えた前記第２繊維樹脂層を、前記第１繊維樹脂層上に形成する、請求項４に記載の基材の製造方法。 The method for manufacturing a substrate according to claim 4, wherein in the lamination step, the second fiber resin layer including a fiber C3 layer laminated on the fiber C2 layer, the fiber C3 being longer than the fiber C2, is formed on the first fiber resin layer. 前記粉砕物をふるいにかけることにより、前記粉砕物を、前記繊維Ｃのうち繊維Ｃ１を含む繊維Ｃ１体と、前記繊維Ｃのうち前記繊維Ｃ１よりも長さが短い繊維Ｃ２を含む繊維Ｃ２体と、に分ける工程を含み、
前記積層工程では、
前記繊維Ｃ１体を層状にしてなる繊維Ｃ１層と、
前記繊維Ｃ１層上に前記繊維Ｃ２体を層状に積層してなる繊維Ｃ２層と、を備えた前記第２繊維樹脂層を、前記第１繊維樹脂層上に形成する、請求項３に記載の基材の製造方法。 The method includes a step of sieving the pulverized material to separate the pulverized material into a fiber C1 body including fiber C1 of the fibers C and a fiber C2 body including fiber C2 of the fibers C that is shorter in length than the fibers C1;
In the lamination step,
A fiber C1 layer formed by layering the fiber C1 body;
The method for manufacturing a substrate according to claim 3, further comprising forming the second fiber resin layer on the first fiber resin layer, the second fiber resin layer including a fiber C2 layer formed by stacking the fiber C2 bodies in layers on the fiber C1 layer. 前記積層工程では、
前記第１繊維樹脂層を搬送部上に形成し、前記第１繊維樹脂層を前記搬送部によって所定方向に搬送し、
前記搬送部によって搬送される前記第１繊維樹脂層を、前記搬送部の下方から吸引部によって吸引した状態で、前記第２繊維樹脂層と前記第３繊維樹脂層とを形成する、請求項３または請求項４に記載の基材の製造方法。 In the lamination step,
forming the first fiber resin layer on a conveying section, and conveying the first fiber resin layer in a predetermined direction by the conveying section;
The method for manufacturing a substrate according to claim 3 or claim 4, wherein the second fiber resin layer and the third fiber resin layer are formed in a state in which the first fiber resin layer transported by the transport section is sucked by a suction section from below the transport section. 請求項３または請求項４に記載の工程を行って製造された基材を加熱し、加熱された前記基材を上型と下型との間に挟んでプレスする工程を含む、乗物用内装材の製造方法。 A method for manufacturing interior materials for vehicles, comprising the steps of heating a substrate manufactured by carrying out the steps according to claim 3 or 4, and pressing the heated substrate by sandwiching it between an upper mold and a lower mold.
JP2022170536A 2022-10-25 2022-10-25 Substrate, method for manufacturing substrate, and method for manufacturing vehicle interior material Pending JP2024062592A (en)

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