JP4299684B2 - Manufacturing method for interior materials - Google Patents
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- JP4299684B2 JP4299684B2 JP2004011657A JP2004011657A JP4299684B2 JP 4299684 B2 JP4299684 B2 JP 4299684B2 JP 2004011657 A JP2004011657 A JP 2004011657A JP 2004011657 A JP2004011657 A JP 2004011657A JP 4299684 B2 JP4299684 B2 JP 4299684B2
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Description
本発明は、合成樹脂からなる芯材とこの芯材の合成樹脂と相溶性が悪い合成樹脂からなる合成樹脂部材とを一体化した内装材の製造方法に関するものである。 The present invention relates to a method for manufacturing an interior material in which a core material made of a synthetic resin and a synthetic resin member made of a synthetic resin that is poorly compatible with the synthetic resin of the core material are integrated.
車両や建築物の内装材は、内装材の形状を保持し剛性を備える合成樹脂の芯材と、芯材の表面に貼着したクッション性、装飾性を備えた合成樹脂の表皮とからなる積層成形体として構成されている。例えば、木質繊維とポリプロピレン樹脂繊維とからなるマットをプレスして成形した木質繊維板と、TPO（サーモプラスチックオレフィン）表皮層の裏面にポリエチレン樹脂フォームのクッション層が裏打ちされた表皮を用意し、この木質繊維板を加熱した後、その上にクッション層を下側にして表皮を載置し、冷間プレスして所定形状に一体成形した内装材がある（特許文献１参照。）。この内装材によれば、プレス一工程で芯材と表皮とを一体化することができる。
最近、環境問題に対して、廃棄時の環境負荷低減を目的に生分解性を有する合成樹脂あるいは非石油系合成樹脂がよく使用されるようになり、特に非石油系であり、かつ生分解性を有するポリ乳酸樹脂が好ましく使用されている。しかし、上記技術で、ポリプロピレン樹脂繊維をポリ乳酸樹脂繊維に代えた木質繊維板とポリエチレン樹脂フォームが裏打ちされた表皮とで成形を行うと、ポリエステル系のポリ乳酸樹脂とポリオレフィン系のポリエチレン樹脂フォームとは相溶性が悪いため、木質繊維板から成形される芯材と表皮とが接着せず、一体化することができない。 Recently, for environmental problems, synthetic resins or non-petroleum synthetic resins having biodegradability are often used for the purpose of reducing the environmental load at the time of disposal, especially non-petroleum and biodegradable. A polylactic acid resin having is preferably used. However, when molding is performed with a wood fiber board in which polypropylene resin fibers are replaced with polylactic acid resin fibers and a skin lined with polyethylene resin foam, the polyester-based polylactic acid resin and the polyolefin-based polyethylene resin foam Since the compatibility is poor, the core material formed from the wood fiber board and the skin do not adhere and cannot be integrated.
本発明の目的は、かかる問題点に鑑み、合成樹脂からなる芯材とこの芯材の合成樹脂と相溶性が悪い合成樹脂部材とを、十分な接着強度を備えて一体化した内装材の製造方法を提供することにある。 In view of such problems, an object of the present invention is to manufacture an interior material in which a core material made of a synthetic resin and a synthetic resin member having poor compatibility with the synthetic resin of the core material are integrated with sufficient adhesive strength. To provide a method.
上記の目的を達成するため、本発明の各発明は次の手段をとる。
先ず請求項１に係る発明は、表皮と一体化した内装材の製造方法であって、第１合成樹脂の繊維体と植物繊維体とからなる第1繊維マットに当該第１合成樹脂とは相溶性の悪い第２合成樹脂の繊維体からなる第２繊維マットを積層した状態で、それぞれの繊維を交絡させて繊維重合体とする交絡工程と、
前記繊維重合体を加熱して、前記第１合成樹脂の繊維体および前記第２合成樹脂の繊維体を溶融させる加熱工程と、
加熱した前記繊維重合体の前記第２繊維マット側に前記第２合成樹脂と相溶性のある第３合成樹脂の層を有する表皮を当該第３合成樹脂の層が相対するように位置させた状態で、所定形状の型間でプレス成形するプレス工程とからなることを特徴とする。
請求項２に係る発明は、請求項１に記載された表皮と一体化した内装材の製造方法であって、前記第１合成樹脂はポリエステル系樹脂であり、前記第２合成樹脂および第３合成樹脂はポリオレフィン系樹脂であることを特徴とする。
請求項３に係る発明は、請求項２に記載された表皮と一体化した内装材の製造方法であって、前記第１合成樹脂はポリ乳酸樹脂であり、前記第２合成樹脂および第３合成樹脂はポリプロピレン樹脂であることを特徴とする。
請求項４に係る発明は、被着体と一体化した内装材の製造方法であって、第１合成樹脂の繊維体と植物繊維体とからなる第1繊維マットに第1合成樹脂とは相溶性の悪い前記第２合成樹脂の繊維体からなる第２繊維マットを積層した状態で、それぞれの繊維を交絡させて繊維重合体とする交絡工程と、
前記繊維重合体を加熱して、前記第１合成樹脂の繊維体および第２合成樹脂の繊維体を溶融させた後、当該繊維重合体をプレスして繊維重合体板を成形する工程と、
前記繊維重合体板の前記第２繊維マットから成形された表面層側に前記第２合成樹脂と相溶性のある第３合成樹脂からなる被着体を所定の位置に設置し、当該被着体と当該表面層を溶着する工程とからなることを特徴とする。
請求項５に係る発明は、請求項４に記載された被着体と一体化した内装材の製造方法であって、前記第１合成樹脂はポリエステル系樹脂であり、前記第２合成樹脂および第３合成樹脂はポリオレフィン系樹脂であることを特徴とする。
請求項６に係る発明は、請求項５に記載された被着体と一体化した内装材の製造方法であって、前記第１合成樹脂はポリ乳酸樹脂であり、前記第２合成樹脂および第３合成樹脂はポリプロピレン樹脂であることを特徴とする。
In order to achieve the above object, each invention of the present invention takes the following means.
The invention according to claim 1 is a method for producing an interior material integrated with an outer skin, wherein the first synthetic resin is combined with a first fiber mat comprising a fiber body of a first synthetic resin and a plant fiber body. In a state where the second fiber mat made of the fiber body of the second synthetic resin having poor solubility is laminated, the entanglement step of making each fiber entangled into a fiber polymer,
A heating step of heating the fiber polymer to melt the fiber body of the first synthetic resin and the fiber body of the second synthetic resin;
A state in which an outer skin having a layer of a third synthetic resin compatible with the second synthetic resin on the second fiber mat side of the heated fiber polymer is positioned so that the layer of the third synthetic resin faces each other And a pressing step of press molding between molds having a predetermined shape.
The invention according to claim 2 is a method of manufacturing an interior material integrated with the skin according to claim 1, wherein the first synthetic resin is a polyester resin, and the second synthetic resin and the third synthetic resin are manufactured. The resin is a polyolefin resin.
The invention according to claim 3 is a method of manufacturing an interior material integrated with the skin according to claim 2, wherein the first synthetic resin is a polylactic acid resin, and the second synthetic resin and the third synthetic resin are produced. The resin is a polypropylene resin.
The invention according to claim 4 is a method for producing an interior material integrated with an adherend, wherein the first synthetic resin is combined with a first fiber mat comprising a fiber body of a first synthetic resin and a plant fiber body. In a state where the second fiber mat composed of the fiber body of the second synthetic resin having poor solubility is laminated, the entanglement step of entanglement of each fiber to form a fiber polymer,
Heating the fiber polymer to melt the fiber body of the first synthetic resin and the fiber body of the second synthetic resin, and then pressing the fiber polymer to form a fiber polymer plate;
An adherend made of a third synthetic resin that is compatible with the second synthetic resin is placed at a predetermined position on the surface layer side formed from the second fiber mat of the fiber polymer plate, and the adherend And a step of welding the surface layer.
The invention according to claim 5 is a method for producing an interior material integrated with an adherend according to claim 4, wherein the first synthetic resin is a polyester-based resin, and the second synthetic resin and the first synthetic resin 3. The synthetic resin is a polyolefin resin.
The invention according to claim 6 is a method of manufacturing an interior material integrated with an adherend according to claim 5, wherein the first synthetic resin is a polylactic acid resin, and the second synthetic resin and the first synthetic resin 3 The synthetic resin is a polypropylene resin.
請求項１に係る発明によれば、第1合成樹脂の繊維体と植物繊維とからなる第1繊維マットと第１合成樹脂と相溶性が悪い第２合成樹脂の繊維体からなる第２繊維マットを積層し、それぞれの繊維マットの繊維を交絡させるため、第２合成樹脂の繊維体が第１繊維マット内に、第１合成樹脂の繊維体および植物繊維体が第２繊維マット内に入り込んだ繊維重合体が成形される。この繊維重合体を加熱し、第１合成樹脂の繊維体および第２合成樹脂の繊維体を溶融させ、この加熱された繊維重合体の第２繊維マット側に第２合成樹脂と相溶性がある第３合成樹脂の層を有する表皮のこの第３合成樹脂の層が相対するように位置させた状態でプレスすることにより第1繊維マットは基体層、第２繊維マットは表面層にそれぞれ成形され、互いの繊維マットの繊維体が交絡した状態で硬化するのでアンカー効果により、互いに相溶性が悪い合成樹脂からなる表面層と基体層とは強固に結合される。
次に、表皮の第３合成樹脂の層が、加熱された繊維重合体の表面層と当接することにより加熱されて軟化する。この軟化した第３合成樹脂の層と繊維重合体の表面層とが相溶し、この状態で硬化することで表皮と表面層が結合される。
これにより、基体層とこの基体層に用いられている合成樹脂と相溶性が悪い合成樹脂からなる表皮とを十分な接着強度を備えて一体化した内装材を製造することができる。
請求項２に係る発明によれば、上述した請求項１の発明において、第1合成樹脂をポリエステル系樹脂、第２合成樹脂および第３合成樹脂をポリオレフィン系樹脂にするため、基体層は耐熱性、強度のある芯材となり、表皮は発泡、シボ転写等の加工が容易なクッション体または意匠シートとなり、クッション性または意匠性を備えた内装材を製造することができる。
請求項３に係る発明によれば、上述した請求項２の発明において、第1合成樹脂を非石油系であり生分解性を有するポリ乳酸樹脂、第２合成樹脂および第３合成樹脂を汎用樹脂であるポリプロプレン樹脂にすることにより、非石油系材料を多く含む内装材を製造することができる。
請求項４に係る発明によれば、請求項１に係る発明と同様に交絡工程と加熱工程を経て第1繊維マットと第２繊維マットとからなる加熱された繊維重合体とする。この繊維重合体をプレスすることにより、請求項１と同様の作用で互いに相溶性が悪い合成樹脂からなる基体層と表面層とが強固に結合された繊維重合体板が成形される。
この繊維重合体板の表面層側に第２合成樹脂と相溶性がある第３合成樹脂からなる被着体を所定の位置に設置させ、被着体と表面層とを溶着することで被着体と表面層が結合される。
これにより、基体層とこの基体層に用いられている合成樹脂と相溶性が悪い合成樹脂からなる被着体とを十分な接着強度を備えて一体化した内装材を製造することができる。
請求項５に係る発明によれば、上述した請求項４の発明において、第1合成樹脂をポリエステル樹脂、第２合成樹脂および第３合成樹脂をポリオレフィン樹脂にするため、基体層は耐熱性、強度のある芯材となり、被着体は発泡、射出成形等の成形が容易な樹脂部材となり、コスト低減された樹脂部材を部分的に取り付けた耐熱性、強度を備えた内装材を製造することができる。
請求項６に係る発明によれば、上述した請求項５の発明において、第1合成樹脂を非石油系であり生分解性を有するポリ乳酸樹脂、第２合成樹脂および第３合成樹脂を汎用樹脂であるポリプロプレン樹脂にすることにより、非石油系材料を多く含む内装材を製造することができる。
According to the first aspect of the present invention, the first fiber mat composed of the first synthetic resin fiber body and the plant fiber, and the second fiber mat composed of the second synthetic resin fiber body having poor compatibility with the first synthetic resin. In order to interlace the fibers of the respective fiber mats, the second synthetic resin fiber body entered the first fiber mat, and the first synthetic resin fiber body and plant fiber body entered the second fiber mat. A fiber polymer is formed. The fiber polymer is heated to melt the first synthetic resin fiber body and the second synthetic resin fiber body, and the second fiber mat side of the heated fiber polymer is compatible with the second synthetic resin. The first fiber mat is formed into a base layer and the second fiber mat is formed into a surface layer by pressing the third synthetic resin layer of the skin having the third synthetic resin layer so that the third synthetic resin layer faces each other. Since the fiber mats of the fiber mats are cured in an entangled state, the surface layer and the base layer made of synthetic resin having poor compatibility with each other are firmly bonded by the anchor effect.
Next, the third synthetic resin layer of the skin is heated and softened by coming into contact with the surface layer of the heated fiber polymer. The softened third synthetic resin layer and the surface layer of the fiber polymer are compatible with each other, and the skin and the surface layer are bonded together by curing in this state.
As a result, it is possible to manufacture an interior material in which a base layer and a skin made of a synthetic resin that is poorly compatible with the synthetic resin used in the base layer are integrated with sufficient adhesive strength.
According to the invention of claim 2, in the invention of claim 1 described above, since the first synthetic resin is a polyester resin and the second synthetic resin and the third synthetic resin are polyolefin resins, the base layer is heat resistant. It becomes a strong core material, and the skin becomes a cushion body or a design sheet that can be easily processed such as foaming and embossing transfer, and an interior material having cushioning properties or design properties can be manufactured.
According to the invention of claim 3, in the invention of claim 2 described above, the first synthetic resin is non-petroleum and biodegradable polylactic acid resin, the second synthetic resin and the third synthetic resin are general-purpose resins. By using a polypropylene resin as described above, an interior material containing a large amount of non-petroleum material can be produced.
According to the fourth aspect of the present invention, a heated fiber polymer composed of the first fiber mat and the second fiber mat is obtained through the entanglement step and the heating step as in the case of the first aspect. By pressing this fiber polymer, a fiber polymer plate in which the base layer and the surface layer made of a synthetic resin having poor compatibility with each other are firmly bonded is formed in the same manner as in the first aspect.
An adherend made of a third synthetic resin that is compatible with the second synthetic resin is placed at a predetermined position on the surface layer side of the fiber polymer plate, and the adherend is adhered to the surface layer by welding. The body and surface layer are combined.
As a result, it is possible to manufacture an interior material in which a base layer and an adherend made of a synthetic resin having poor compatibility with the synthetic resin used in the base layer are integrated with sufficient adhesive strength.
According to the invention of claim 5, in the invention of claim 4 described above, since the first synthetic resin is a polyester resin, and the second synthetic resin and the third synthetic resin are polyolefin resins, the base layer has heat resistance and strength. It is possible to produce an interior material with heat resistance and strength by partially attaching a resin member whose cost has been reduced, and the adherend becomes a resin member that can be easily molded such as foaming and injection molding. it can.
According to the invention of claim 6, in the invention of claim 5 described above, the first synthetic resin is non-petroleum and biodegradable polylactic acid resin, second synthetic resin and third synthetic resin are general-purpose resins. By using a polypropylene resin as described above, an interior material containing a large amount of non-petroleum material can be produced.
次に、本発明の実施するための最良の形態ついて詳細に説明する。
本発明の第一実施の形態について図１、図２を用いて説明する。図１は本発明により製造された第一実施形態の内装材断面図、図２（ａ）は交絡工程後の繊維重合体の断面図、図２（ｂ）は加熱工程後の繊維重合体の断面図、図２（ｃ）はプレス工程時の繊維重合体と表皮の断面図である。
Next, the best mode for carrying out the present invention will be described in detail.
A first embodiment of the present invention will be described with reference to FIGS. 1 is a cross-sectional view of an interior material of a first embodiment manufactured according to the present invention, FIG. 2 (a) is a cross-sectional view of a fiber polymer after an entanglement step, and FIG. 2 (b) is a view of the fiber polymer after a heating step. Sectional drawing and FIG.2 (c) are sectional drawings of the fiber polymer and skin at the time of a press process.
図１に示す第一実施形態に係る内装材１の製造方法は、図２（ａ）、図２（ｂ）、図２（ｃ）で示すように第１合成樹脂の繊維体１１ａと植物繊維１４ａとからなる第１繊維マット１１１の上に第２合成樹脂の繊維体１２ａからなる第２繊維マット１２２を積層させた積層繊維マットを交絡部材４にて交絡し、繊維重合体１７７とする交絡工程と、当該繊維重合体１７７を加熱し第１合成樹脂の繊維体１１ａおよび第２合成樹脂の繊維体１２ａを溶融させる加熱工程と、加熱された繊維重合体１７７の第２繊維マット１２２側に第３合成樹脂の層を有する表皮１３を第３合成樹脂の層が相対するように位置させてプレスするプレス工程とからなる。 The manufacturing method of the interior material 1 according to the first embodiment shown in FIG. 1 includes a fiber body 11a of first synthetic resin and plant fibers as shown in FIGS. 2 (a), 2 (b), and 2 (c). The entangled member 4 entangles the laminated fiber mat obtained by laminating the second fiber mat 122 made of the second synthetic resin fiber body 12a on the first fiber mat 111 made of 14a to form the fiber polymer 177. A step of heating the fiber polymer 177 to melt the first synthetic resin fiber body 11a and the second synthetic resin fiber body 12a, and the heated fiber polymer 177 on the second fiber mat 122 side. The pressing step includes pressing the outer skin 13 having the third synthetic resin layer so that the third synthetic resin layer faces the outer skin 13.
（ａ．交絡工程）
まず、第1合成樹脂の繊維体１１ａと植物繊維１４ａとを混合し、公知のカード機、エアレイによる開繊方法により混合繊維からなる第1繊維マット１１１を作成する。同様に第２合成樹脂の繊維体を積層させ、第２繊維マット１２２を作成し、第1繊維マット１１１の上に第２繊維マット１２２を載置し、積層繊維マットとする。
この積層繊維マットは、第１繊維マット１１１と第２繊維マットを別々に作成した後、積層させているが、第１繊維マット１１１の上から第２合成樹脂の繊維体１２ａを堆積させる方法でもよい。
また、第1合成樹脂の繊維体１１ａの混率は第1繊維マット１１１重量の１０〜９０重量％が好ましい、また、混率を９０重量％以下にすることにより剛性、曲げ強さの強い内装材１となり好ましい。
次に、この積層繊維マットを上から積層繊維マット厚さ方向に複数の線条の突起４ｂが形成された交絡部材４で刺し込み、第２繊維マット１２２の第２合成樹脂繊維１２ａと第１繊維マット１１１の第１合成樹脂繊維１１ａおよび植物繊維１４ａとを交絡させた繊維重合体１７７を成形する。交絡部材４で刺し込みは、第1繊維マット１１１の側から行っても良い。
また、第１繊維マット１１１、第２繊維マット１２２は一方の繊維を他方の繊維マットに入れ込みやすくするために交絡されていないウェブであることが好ましい。
第１合成樹脂の繊維体１１ａは、植物繊維１４ａ同士を結合させることができる熱可塑性樹脂であり、例えば、ポリオレフィン系樹脂、ポリエステル系樹脂が使用できる。
植物繊維１４ａは、木質系や草本系のセルロース材料であり、具体的には、木材パルプ、バガス、木綿、ケナフ、ジュート、ヘンプ、サイザル等があげられるが、長繊維が得られやすく生産性のよい、ケナフの靭皮繊維が好ましい。
第２合成樹脂の繊維体１２ａは、第1合成樹脂と相溶性が悪い熱可塑性樹脂であり、第１合成樹脂がポリオレフィン系樹脂であれば、第２合成樹脂はポリエステル系樹脂であり、第１合成樹脂がポリエステル系樹脂であれば、第２合成樹脂はポリオレフィン系樹脂である。
(A. Entanglement process)
First, the fiber body 11a of the first synthetic resin and the plant fiber 14a are mixed, and a first fiber mat 111 made of the mixed fiber is prepared by a known carding machine and an opening method using an air lay. Similarly, fiber bodies of the second synthetic resin are laminated to form a second fiber mat 122, and the second fiber mat 122 is placed on the first fiber mat 111 to form a laminated fiber mat.
In this laminated fiber mat, the first fiber mat 111 and the second fiber mat are separately formed and then laminated, but the method of depositing the fiber body 12a of the second synthetic resin on the first fiber mat 111 is also possible. Good.
Further, the mixing ratio of the first synthetic resin fibrous body 11a is preferably 10 to 90 wt% of the weight of the first fiber mat 111, and the interior material 1 having high rigidity and bending strength by setting the mixing ratio to 90 wt% or less. It is preferable.
Next, the laminated fiber mat is inserted from above with the entangled member 4 in which a plurality of linear protrusions 4b are formed in the laminated fiber mat thickness direction, and the second synthetic resin fibers 12a and the first synthetic fiber fibers 12a of the second fiber mat 122 are inserted. A fiber polymer 177 in which the first synthetic resin fibers 11a and the plant fibers 14a of the fiber mat 111 are entangled is formed. Stitching with the entanglement member 4 may be performed from the first fiber mat 111 side.
Further, the first fiber mat 111 and the second fiber mat 122 are preferably webs that are not entangled in order to make it easier to insert one fiber into the other fiber mat.
The fibrous body 11a of the first synthetic resin is a thermoplastic resin that can bond the plant fibers 14a to each other. For example, a polyolefin resin or a polyester resin can be used.
The plant fiber 14a is a woody or herbaceous cellulosic material, and specifically includes wood pulp, bagasse, cotton, kenaf, jute, hemp, sisal, etc., but long fibers are easily obtained and have high productivity. Good kenaf bast fibers are preferred.
The fibrous body 12a of the second synthetic resin is a thermoplastic resin having poor compatibility with the first synthetic resin. If the first synthetic resin is a polyolefin resin, the second synthetic resin is a polyester resin. If the synthetic resin is a polyester resin, the second synthetic resin is a polyolefin resin.
（ｂ．加熱工程）
繊維重合体１７７を加熱する。
繊維重合体１７７は加熱プレス装置５により、第1合成樹脂の繊維体１１ａと第２合成樹脂の繊維体１２ａが溶融するように加熱プレスされ、密度が増加し、板厚の薄いものとなる。
加熱プレス装置５は加熱された上下型でプレスする公知の技術であり、型温度は第１合成樹脂の繊維体１１ａおよび第２合成樹脂の繊維体１２ａが溶融する温度に適宜設定される。ここで、繊維重合体１７７の加熱プレスは、ヒーターによる加熱だけでもよいが、ハンドリング性、植物繊維１４ａの炭化防止の点からプレスを行い繊維重合体１７７の密度を大きくすることが好ましい。
(B. Heating step)
The fiber polymer 177 is heated.
The fiber polymer 177 is heated and pressed by the heating press device 5 so that the first synthetic resin fiber body 11a and the second synthetic resin fiber body 12a are melted, and the density is increased and the sheet thickness is reduced.
The heating press device 5 is a known technique for pressing with a heated upper and lower mold, and the mold temperature is appropriately set to a temperature at which the fibrous body 11a of the first synthetic resin and the fibrous body 12a of the second synthetic resin are melted. Here, the heating press of the fiber polymer 177 may be only heating with a heater, but it is preferable to increase the density of the fiber polymer 177 by pressing from the viewpoint of handling properties and prevention of carbonization of the plant fiber 14a.
（ｃ．プレス工程）
繊維重合体１７７および表皮１３をプレスする。
まず、加熱された繊維重合体１７７を上下型７の下型７ａに載置し、第３合成樹脂の層である合成樹脂フォーム１３ｃを有する表皮１３を、合成樹脂フォーム１３ｃが下になるように上型７ｂに設置する。
表皮１３は、意匠となる意匠シート１３ｂの裏面に第３合成樹脂からなる第３合成樹脂層である合成樹脂フォーム１３ｃが貼着されたものである。
意匠シート１３bは、内装材の意匠となり、様々な模様が印刷され、またシボ等の凹凸模様が形成されている。材料としては、塩ビ、TPO（サーモプラスチックオレフィン）等の熱可塑性樹脂シート、織布、不織布等が使用される。
合成樹脂フォーム１３ｃの第３合成樹脂は、第1合成樹脂と相溶性が悪く、第２合成樹脂と相溶性があり、第２合成樹脂がポリオレフィン系樹脂であれば第３合成樹脂はポリオレフィン系樹脂であり、第２合成樹脂がポリエステル系樹脂であれば第３合成樹脂はポリエステル系樹脂である。合成樹脂フォーム１３ｃは、第３合成樹脂を公知の発泡技術で発泡成形されたものであり、ポリエチレン樹脂フォーム、ポリプロピレン樹脂フォームがコスト面から好ましく使用される。
また、第３合成樹脂層として今回は合成樹脂フォームとしたが、シート状のものであってもよく、表皮１３は成形性を向上させるために事前に加熱されていてもよい。
次に、表皮１３を上型７ｂへ設置するが、図示されない吸引装置により上型７ｂの型表面に吸着させる方法、または、図示されないクランプ装置で固定する方法等、公知の技術で行われる。
繊維重合体１７７および表皮１３を上下型７に設置した後、図示しないプレス装置で上型７ｂを下型７ａに接近させる型締により冷間プレスする。ここで、第1繊維マット１１１は基体層１１、第２繊維マット１２２は表面層１２にそれぞれ成形され、互いの繊維マットの繊維体が交絡した状態で硬化し、表皮１３の合成樹脂フォーム１３ｃが、表面層１２と相溶し、硬化する。
これにより、基体層１１と表皮１３とを十分な接着強度を備えて一体化した内装材が製造される。
(C. Pressing process)
The fiber polymer 177 and the skin 13 are pressed.
First, the heated fiber polymer 177 is placed on the lower mold 7 a of the upper and lower molds 7, and the skin 13 having the synthetic resin foam 13 c as the third synthetic resin layer is placed so that the synthetic resin foam 13 c is on the lower side. Installed in the upper mold 7b.
The skin 13 is obtained by attaching a synthetic resin foam 13c, which is a third synthetic resin layer made of a third synthetic resin, to the back surface of a design sheet 13b serving as a design.
The design sheet 13b becomes a design of an interior material, on which various patterns are printed, and uneven patterns such as wrinkles are formed. As the material, polyvinyl chloride, thermoplastic resin sheets such as TPO (thermoplastic olefin), woven fabric, non-woven fabric, etc. are used.
The third synthetic resin of the synthetic resin foam 13c is poorly compatible with the first synthetic resin and compatible with the second synthetic resin. If the second synthetic resin is a polyolefin resin, the third synthetic resin is a polyolefin resin. If the second synthetic resin is a polyester resin, the third synthetic resin is a polyester resin. The synthetic resin foam 13c is obtained by foaming a third synthetic resin by a known foaming technique, and a polyethylene resin foam or a polypropylene resin foam is preferably used from the viewpoint of cost.
In addition, although the synthetic resin foam is used as the third synthetic resin layer this time, it may be a sheet and the skin 13 may be heated in advance in order to improve moldability.
Next, the skin 13 is placed on the upper mold 7b, and a known technique such as a method of adsorbing to the mold surface of the upper mold 7b with a suction device (not shown) or a method of fixing with a clamp device (not shown) is performed.
After the fiber polymer 177 and the skin 13 are placed on the upper and lower molds 7, cold pressing is performed by clamping the upper mold 7 b closer to the lower mold 7 a with a pressing device (not shown). Here, the first fiber mat 111 is formed on the base layer 11 and the second fiber mat 122 is formed on the surface layer 12, and is cured in a state where the fiber bodies of the respective fiber mats are entangled, and the synthetic resin foam 13c of the skin 13 is formed. It is compatible with the surface layer 12 and cured.
Thereby, an interior material in which the base layer 11 and the skin 13 are integrated with sufficient adhesive strength is manufactured.
本発明の第二実施の形態について図２、図３、図４を用いて説明する。図３は本発明により製造された第二の実施形態の内装材断面図、図４は溶着工程時の繊維重合体板の断面図である。尚、第一実施形態と同じ部分については同じ記号で示す。 A second embodiment of the present invention will be described with reference to FIGS. FIG. 3 is a cross-sectional view of the interior material of the second embodiment manufactured according to the present invention, and FIG. 4 is a cross-sectional view of the fiber polymer plate during the welding process. In addition, about the same part as 1st embodiment, it shows with the same symbol.
図３に示す第二実施例に係る内装材１の製造方法は、図２（ａ）、図２（ｂ）で示す第一実施例の交絡工程および加熱工程と、繊維重合体１７７をプレスして繊維重合体板１７を成形する繊維重合体板成形工程と図４で示すように繊維重合体板１７の表面層１２と被着体１３とを溶着する溶着工程とからなる。 The manufacturing method of the interior material 1 according to the second embodiment shown in FIG. 3 is the press of the entanglement process and heating process of the first embodiment shown in FIG. 2 (a) and FIG. The fiber polymer plate forming step for forming the fiber polymer plate 17 and the welding step for welding the surface layer 12 of the fiber polymer plate 17 and the adherend 13 as shown in FIG.
ｄ．繊維重合体板成形工程
繊維重合体１７７をプレスする。
プレスは、第一実施例と同様に交絡工程および加熱工程を経た繊維重合体１７７を、所定形状を備える上下型により行う。
プレスされた繊維重合体１７７は、繊維重合体１７７下層の第1繊維マット１１１が基体層１１に繊維重合体７上層の第２繊維マット１２２が表面層１２に成形された繊維重合体板１７となる。
d. Fiber polymer plate forming step The fiber polymer 177 is pressed.
The press is performed by an upper and lower mold having a predetermined shape for the fiber polymer 177 that has undergone the entanglement process and the heating process as in the first embodiment.
The pressed fiber polymer 177 includes a fiber polymer plate 17 in which the first fiber mat 111 in the lower layer of the fiber polymer 177 is formed in the base layer 11 and the second fiber mat 122 in the upper layer of the fiber polymer 7 is formed in the surface layer 12. Become.
ｅ．溶着工程
被着体である係止部材１３を繊維重合体板１７の表面層１２と溶着させる。
係止部材１３は、内装材１を図示しない他の物体に取り付けるためのものであり、先端に図示しない他の物体に形成された係止孔に係止する係止爪が形成された柱状の係止片１３ｄと、係止片１３ｄの係止爪のない末端に一体化された接合プレート１３ｅからなる。
接合プレート１３ｅは、第３合成樹脂からなるプレートであり、係止片１３ｄに繊維重合体板１７と平行になるように係止片１３ｄに形成されている。
まず、係止部材１３の接合プレート１３ｅを繊維重合体板１７の表面層１２上に当接するように設置する。
次に係止部材１３側から接合プレート１３ｅをコの字型のウェルダーバー９ｂで押し付けるとともに係止片１３ｄをウェルダーバー９ｂのコの字部分と嵌合させ、ウェルダーバー９ｂを左右に振動させる。この振動による摩擦熱で接合プレート１３ｅと表面層１２が接触する部分が溶融して溶着する。
これにより、基体層１１と係止部材１３とを十分な接着強度を備えて一体化した内装材が製造される。また、溶着は上下振動による超音波溶着によって行ってもよい。
e. Welding process The locking member 13, which is an adherend, is welded to the surface layer 12 of the fiber polymer plate 17.
The locking member 13 is for attaching the interior material 1 to another object (not shown), and has a columnar shape in which a locking claw for locking to a locking hole formed in another object (not shown) is formed at the tip. It consists of a locking piece 13d and a joining plate 13e integrated at the end of the locking piece 13d without a locking claw.
The joining plate 13e is a plate made of a third synthetic resin, and is formed on the locking piece 13d so as to be parallel to the fiber polymer plate 17 on the locking piece 13d.
First, the joining plate 13 e of the locking member 13 is installed so as to abut on the surface layer 12 of the fiber polymer plate 17.
Next, the joining plate 13e is pressed from the side of the locking member 13 with the U-shaped welder bar 9b, and the locking piece 13d is fitted to the U-shaped portion of the welder bar 9b to vibrate the welder bar 9b to the left and right. The portion where the bonding plate 13e and the surface layer 12 contact is melted and welded by the frictional heat generated by the vibration.
Thereby, an interior material in which the base layer 11 and the locking member 13 are integrated with sufficient adhesive strength is manufactured. Further, the welding may be performed by ultrasonic welding by vertical vibration.
今回は、一体化される合成樹脂部品の実施例として、表皮、係止部材を例にあげたが、これらに限定されず、その他ポケット、緩衝材等の内装材に取り付けられるものであってもよい。 This time, as an example of synthetic resin parts to be integrated, the skin and the locking member are taken as an example, but not limited to these, even if attached to interior materials such as pockets and cushioning materials Good.
（実施例１）
ポリ乳酸樹脂繊維とケナフの靭皮からなるケナフ繊維とをエアレイにより開繊して積層させ、ポリ乳酸樹脂繊維とケナフ繊維の重量比が３０：７０である目付け１5００ｇ／ｍ２のポリ乳酸樹脂繊維とケナフ繊維のマットを作成する。また、ポリプロピレン樹脂繊維を同じくエアレイにより開繊して積層させ、目付け１００ｇ／ｍ２のポリプロピレン樹脂繊維のマットを作成する。
次に、ポリプロピレン樹脂繊維のマットをポリ乳酸樹脂繊維とケナフ繊維のマットの上に載置し、ポリプロピレン繊維のマット側からニードルパンチをかけ、ポリプロピレン樹脂繊維をポリ乳酸樹脂繊維とケナフ繊維のマット内に、ポリ乳酸樹脂繊維とケナフ繊維をポリプロピレン樹脂繊維のマット内に入れ込み、板厚１０ｍｍの繊維重合体を作成する。この繊維重合体を加熱プレス装置により、型温２３０℃、プレス時間４０秒間で加熱プレスし、ポリ乳酸樹脂繊維とポリプロピレン樹脂繊維を溶融させ、板厚２．５ｍｍの繊維重合体を成形する。
表皮は０．３５ｍｍのＴＰＯシートに厚さ１ｍｍのポリプロピレン樹脂フォームが裏打ちされたものを使用した。この表皮をヒーターにより１３０℃で４０秒間加熱し、軟化させる。
次に、内装材表面形状を備える上型と内装材裏面形状を備える下型の上下型により冷間プレスを行う。型開きした下型の上に加熱プレスされた繊維重合体を載置し、吸引装置を備える上型に加熱された表皮をポリプロプレン樹脂フォームが下側になるように吸着させ、板厚３．１ｍｍになるように上型を下型に接近させ型締めを行った。型締めを６０秒間行った後、型を開き、繊維重合体から成形された芯材と表皮の積層成形体である内装材を取り出した。
Example 1
And a kenaf fiber consisting of bast polylactic acid resin fiber and kenaf are stacked by spreading by air-laying, the weight ratio of polylactic acid resin fibers and kenaf fibers having a basis weight of 1500 g / m 2 is 30:70 polylactic acid resin fibers And create a mat of kenaf fiber. In addition, the polypropylene resin fibers are similarly spread and laminated by air laying to produce a polypropylene resin fiber mat having a basis weight of 100 g / m 2 .
Next, the polypropylene resin fiber mat is placed on the polylactic acid resin fiber and kenaf fiber mat, and the needle punch is applied from the polypropylene fiber mat side, and the polypropylene resin fiber is placed inside the polylactic acid resin fiber and kenaf fiber mat. Then, the polylactic acid resin fiber and the kenaf fiber are put into a polypropylene resin fiber mat to prepare a fiber polymer having a plate thickness of 10 mm. This fiber polymer is heated and pressed by a hot press apparatus at a mold temperature of 230 ° C. and a pressing time of 40 seconds to melt the polylactic acid resin fiber and the polypropylene resin fiber to form a fiber polymer having a plate thickness of 2.5 mm.
The skin used was a 0.35 mm TPO sheet lined with a 1 mm thick polypropylene resin foam. This skin is heated by a heater at 130 ° C. for 40 seconds to soften.
Next, cold pressing is performed by the upper and lower molds of the upper mold having the interior material surface shape and the lower mold having the interior material back surface shape. 2. The heated and pressed fiber polymer is placed on the opened lower mold, and the heated skin is adsorbed on the upper mold equipped with a suction device so that the polypropylene resin foam is on the lower side. The upper mold was brought close to the lower mold so as to be 1 mm, and the mold was clamped. After performing mold clamping for 60 seconds, the mold was opened, and an interior material that was a laminated molded body of a core material and a skin formed from a fiber polymer was taken out.
（実施例２）
実施例１と同様の加熱プレスされた繊維重合体を作成し、この加熱された繊維重合体を冷間プレスすることで上層がポリプロピレン樹脂層、下層がケナフ繊維を含むポリ乳酸樹脂層である板厚２．５ｍｍの芯材を成形した。
次に、係止片の末端に接合プレートが一体化されているポリプロピレン樹脂からなる係止部材を用意した。この係止部材の接合プレートは４５ｍｍ×４０ｍｍ×１．５ｍｍのプレートであり、係止片は、３０ｍｍ×２０ｍｍ×２５ｍｍの柱状形状をしている。
まず、係止部材の接合プレートを芯材のポリプロピレン樹脂側の上層に当接するように設置する。
次に、コの字型ウェルダ−バーで係止部材側から接合プレートを荷重３３９ｄａＮで圧接させるとともに係止片と嵌合させ、ウェルダーバーを振幅０．６ｍｍ、周波数２４０Ｈｚで３秒間振動させ、接合プレートの２．５ｍｍ×３ｍｍの範囲で芯材と溶着させた。
(Example 2)
A plate having a polypropylene resin layer as an upper layer and a polylactic acid resin layer containing a kenaf fiber as an upper layer by producing a hot-pressed fiber polymer similar to Example 1 and cold-pressing the heated fiber polymer A core material having a thickness of 2.5 mm was formed.
Next, a locking member made of polypropylene resin in which a joining plate was integrated at the end of the locking piece was prepared. The joining plate of this locking member is a 45 mm × 40 mm × 1.5 mm plate, and the locking piece has a columnar shape of 30 mm × 20 mm × 25 mm.
First, the joining plate of the locking member is installed so as to contact the upper layer of the core material on the polypropylene resin side.
Next, with the U-shaped welder bar, the joining plate is pressed from the side of the locking member with a load of 339 daN and fitted with the locking piece, and the welder bar is vibrated at an amplitude of 0.6 mm and a frequency of 240 Hz for 3 seconds. It was made to weld with a core material in the range of 2.5 mm x 3 mm of a plate.
（比較例１）
実施例１と同様にして目付け１5００ｇ／ｍ２のポリ乳酸樹脂繊維とケナフ繊維のマットを作成する。ポリ乳酸樹脂繊維とケナフ繊維のマットを加熱プレス装置により型温２３０℃、プレス時間４０秒間で加熱する。また、実施例１と同じ表皮を用意し、同じ条件で表皮を加熱する。
次に実施例１と同様に上下型による冷間プレス装置により表皮材とポリ乳酸樹脂繊維マットを冷間プレスし、板厚３．１ｍｍの積層成形体である内装材を成形した。
(Comparative Example 1)
In the same manner as in Example 1, a mat of polylactic acid resin fibers and kenaf fibers having a basis weight of 1500 g / m 2 is prepared. The mat of polylactic acid resin fiber and kenaf fiber is heated with a heating press apparatus at a mold temperature of 230 ° C. and a press time of 40 seconds. Moreover, the same skin as Example 1 is prepared and the skin is heated under the same conditions.
Next, similarly to Example 1, the skin material and the polylactic acid resin fiber mat were cold-pressed by a cold press apparatus using an upper and lower mold, and an interior material which was a laminated molded body having a plate thickness of 3.1 mm was formed.
（比較例２）
実施例１のポリ乳酸樹脂繊維に変えてポリプロピレン樹脂繊維にし、ポリプロピレン樹脂繊維とケナフ繊維の重量比が３０：７０である目付１5００ｇ／ｍ２のポリプロピレン樹脂繊維とケナフ繊維のマットを作成する。ポリプロピレン樹脂繊維とケナフ繊維のマットを実施例１と同様に加熱プレス装置により、型温２３０℃、４０秒間で加熱し、ポリプロピレン樹脂繊維を溶融させる。また、実施例１と同じ表皮で同じ条件で表皮を加熱する。
次に実施例１と同様に上下型により表皮材とポリ乳酸樹脂繊維マットを冷間プレスし、板厚３．１ｍｍの積層成形体である内装材を成形した。
(Comparative Example 2)
Polypropylene resin fibers are used instead of the polylactic acid resin fibers of Example 1, and a mat of polypropylene resin fibers and kenaf fibers having a basis weight of 1500 g / m 2 and a weight ratio of polypropylene resin fibers to kenaf fibers of 30:70 is prepared. The mat of polypropylene resin fibers and kenaf fibers is heated in the same manner as in Example 1 by a hot press apparatus at a mold temperature of 230 ° C. for 40 seconds to melt the polypropylene resin fibers. In addition, the same skin as in Example 1 is heated under the same conditions.
Next, similarly to Example 1, the skin material and the polylactic acid resin fiber mat were cold-pressed by the upper and lower molds, and an interior material which was a laminated molded body having a plate thickness of 3.1 mm was molded.
（比較例３）実施例１のポリ乳酸樹脂繊維マットを加熱プレスおよび冷却し、厚さ２．５ｍｍの芯材を作成する。この芯材の上に実施例２と同じ係止部材を設置し、実施例２と同じようにウェルダーバーを振動させ係止部材を芯材に溶着した。 (Comparative Example 3) The polylactic acid resin fiber mat of Example 1 is heated and cooled to produce a core material having a thickness of 2.5 mm. The same locking member as in Example 2 was installed on this core material, and the welder bar was vibrated in the same manner as in Example 2 to weld the locking member to the core material.
得られた実施例および比較例について、表皮と芯材の剥離強度と係止部材と芯材の引張強度を測定した。 For the obtained Examples and Comparative Examples, the peel strength of the skin and the core material and the tensile strength of the locking member and the core material were measured.
（測定１）
実施例１、比較例１、２については、成形した内装材から幅２５ｍｍの試験片を採取し、この試験片の一端を固定し、試験片の他端で芯材と表皮を剥がし、引張り試験機より表皮のみを芯材と表皮との成す角が１８０°となる方向に引張り速度２００ｍｍ／ｍｉｎで引張り、このとき測定される最大荷重を測定する。
(Measurement 1)
For Example 1 and Comparative Examples 1 and 2, a test piece having a width of 25 mm was collected from the molded interior material, one end of this test piece was fixed, the core material and the skin were peeled off at the other end of the test piece, and a tensile test From the machine, only the skin is pulled at a pulling speed of 200 mm / min in the direction in which the angle between the core material and the skin is 180 °, and the maximum load measured at this time is measured.
（測定２）
実施例２、比較例３については、係止部材と芯材の剥離強度を測定した。
係止部材の接合プレートの中点であり、接合プレートから係止部材高さ方向に１０ｍｍの部分を、引張り試験機により係止部材と芯材との接触面垂直方向に引張り速度５００ｍｍ／minで引張り、この時計測される最大荷重を測定する。
(Measurement 2)
For Example 2 and Comparative Example 3, the peel strength between the locking member and the core material was measured.
It is the middle point of the joining plate of the locking member, and a portion of 10 mm from the joining plate in the height direction of the locking member is pulled at a pulling speed of 500 mm / min in the direction perpendicular to the contact surface between the locking member and the core by a tensile tester. Pull and measure the maximum load measured at this time.
結果を図５に示す。
実施例１は比較例２と同様の剥離強度であり、実施例２は比較例３に比べ２倍以上の引張強度を示している。これにより合成樹脂からなる芯材と芯材の合成樹脂と相溶性が悪い合成樹脂からなる表皮または係止部材とを十分な剥離強度、引張強度を備えて一体化することができることが判明した。
The results are shown in FIG.
Example 1 has the same peel strength as that of Comparative Example 2, and Example 2 shows a tensile strength that is twice or more that of Comparative Example 3. As a result, it has been found that a core material made of a synthetic resin and a skin or a locking member made of a synthetic resin having poor compatibility with the synthetic resin of the core material can be integrated with sufficient peel strength and tensile strength.
１ 内装材
４ 交絡部材
４ａ 突起
５ 加熱プレス装置
７ 上下型
７ａ 下型
７ｂ 上型
９ ウェルダー装置
９ｂ ウェルダーバー
１１ 基体層
１１ａ 第１合成樹脂の繊維体
１２ 表面層
１２ａ 第２合成樹脂の繊維体
１３ 表皮、被着体
１３ｂ 意匠シート
１３ｃ 合成樹脂フォーム
１３ｄ 係止片
１３ｅ 接合プレート
１４ａ 植物繊維
１７ 繊維重合体板
１１１ 第１繊維マット
１２２ 第２繊維マット
１７７ 繊維重合体
DESCRIPTION OF SYMBOLS 1 Interior material 4 Interlaced member 4a Protrusion 5 Heat press apparatus 7 Upper and lower mold 7a Lower mold 7b Upper mold 9 Welder apparatus 9b Welder bar 11 Base layer 11a First synthetic resin fiber body 12 Surface layer 12a Second synthetic resin fiber body 13 Skin, adherend 13b Design sheet 13c Synthetic resin foam 13d Locking piece 13e Joining plate 14a Plant fiber 17 Fiber polymer board 111 First fiber mat 122 Second fiber mat 177 Fiber polymer
Claims (6)
前記繊維重合体を加熱して、前記第１合成樹脂の繊維体および前記第２合成樹脂の繊維体を溶融させる加熱工程と、
加熱した前記繊維重合体の前記第２繊維マット側に前記第２合成樹脂と相溶性のある第３合成樹脂の層を有する表皮を当該第３合成樹脂の層が相対するように位置させた状態で、所定形状の型間でプレス成形するプレス工程とからなることを特徴とする表皮と一体化した内装材の製造方法。 In the state where the second fiber mat made of the second synthetic resin fiber body having poor compatibility with the first synthetic resin is laminated on the first fiber mat made of the first synthetic resin fiber body and the plant fiber body, respectively. An entanglement step of entanglement of the fibers into a fiber polymer;
A heating step of heating the fiber polymer to melt the fiber body of the first synthetic resin and the fiber body of the second synthetic resin;
A state in which an outer skin having a layer of a third synthetic resin compatible with the second synthetic resin on the second fiber mat side of the heated fiber polymer is positioned so that the layer of the third synthetic resin faces each other A method for producing an interior material integrated with an outer skin, comprising a pressing step of press molding between molds having a predetermined shape.
前記繊維重合体を加熱して、前記第１合成樹脂の繊維体および前記第２合成樹脂の繊維体を溶融させた後、当該繊維重合体をプレスして繊維重合体板を成形する工程と、
前記繊維重合体板の前記第２繊維マットから成形された表面層側に前記第２合成樹脂と相溶性のある第３合成樹脂からなる被着体を所定の位置に設置し、当該被着体と当該表面層を溶着する工程とからなることを特徴とする被着体と一体化した内装材の製造方法。 The first fiber mat composed of the first synthetic resin fiber body and the plant fiber body is laminated with the second fiber mat composed of the second synthetic resin fiber body having poor compatibility with the first synthetic resin. An entanglement step of entanglement of fibers into a fiber polymer;
Heating the fiber polymer to melt the fiber body of the first synthetic resin and the fiber body of the second synthetic resin, and then pressing the fiber polymer to form a fiber polymer plate;
An adherend made of a third synthetic resin that is compatible with the second synthetic resin is placed at a predetermined position on the surface layer side formed from the second fiber mat of the fiber polymer plate, and the adherend And a step of welding the surface layer. A method for producing an interior material integrated with an adherend.
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