JP2003305789A - Molded interior material and its production method - Google Patents

Molded interior material and its production method

Info

Publication number
JP2003305789A
JP2003305789A JP2002114916A JP2002114916A JP2003305789A JP 2003305789 A JP2003305789 A JP 2003305789A JP 2002114916 A JP2002114916 A JP 2002114916A JP 2002114916 A JP2002114916 A JP 2002114916A JP 2003305789 A JP2003305789 A JP 2003305789A
Authority
JP
Japan
Prior art keywords
fiber
mixture
sheet
interior material
molded interior
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
JP2002114916A
Other languages
Japanese (ja)
Inventor
Masahiko Mikami
正彦 三上
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Sanwa Kogyo Co Ltd
Original Assignee
Sanwa Kogyo Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Sanwa Kogyo Co Ltd filed Critical Sanwa Kogyo Co Ltd
Priority to JP2002114916A priority Critical patent/JP2003305789A/en
Publication of JP2003305789A publication Critical patent/JP2003305789A/en
Pending legal-status Critical Current

Links

Landscapes

  • Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
  • Laminated Bodies (AREA)

Abstract

<P>PROBLEM TO BE SOLVED: To provide a molded interior material which is free from environmental problems when incinerated, excellent in deformation resistance, and light in weight. <P>SOLUTION: In the interior material 1, reinforcing layers 3 and 4 comprising carbon fibers 11 and sisal fibers 12 are arranged on both sides of a polyurethane base material layer 2, and a skin layer 5 and mold release layer 6 are arranged on the outside of the reinforcing layers 3 and 4. <P>COPYRIGHT: (C)2004,JPO

Description

【発明の詳細な説明】Detailed Description of the Invention

【０００１】[0001]

【発明の属する技術分野】本発明は、形状安定性に優れ
た軽量の車両用成形天井材、成形ドアトリム、リヤパッ
ケージトレイ、トノボード、車両用フロア材等の成形内
装材に関する。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a lightweight molded ceiling material, a molded door trim, a rear package tray, a tonneau board, a vehicle floor material, and the like, which are lightweight and have excellent shape stability.

【０００２】[0002]

【従来の技術】従来より、熱成形可能な硬質フォーム等
からなる基材層の両面に、この基材層を補強、強化する
ためのガラス繊維層等の補強層を形成し、このガラス繊
維層等の表面に表皮層及び裏面層を設けた車両用成形天
井材等の成形内装材が知られている。これらの成形天井
の製造方法としては、補強用シートもしくは基材層に熱
可塑性樹脂を塗布したものを用意し、表皮、補強用シー
ト、基材層、補強用シート、離面紙を重ね、熱プレスで
板状積層体を作成しておく。そして、必要な時に、この
積層体を予熱し、常温のプレス成形型で加圧成形するコ
ールドプレス方法と、補強用シートもしくは基材層に熱
硬化性樹脂を塗布したものを用意し、表皮、補強用シー
ト、基材層、補強用シート、離面紙を重ね、加熱したプ
レス成形型で加圧成形するホットプレス方法とが知られ
ている。なお、透過性を防止するために、表皮と補強層
との間にフィルムを挿入することも知られている。この
ような成形天井の例としては、例えば、特開平０８−２
４６３１５号公報、特開平０９−２７７４１５号公報、
特開平１０−０００７１６号公報等に開示されているも
のが知られている。2. Description of the Related Art Conventionally, a reinforcing layer such as a glass fiber layer for reinforcing and strengthening the base material layer has been formed on both sides of a base material layer made of a thermoformable hard foam or the like. A molded interior material such as a molded ceiling material for vehicles having a surface layer and a back surface layer provided on the surface thereof is known. As a method for manufacturing these molded ceilings, a reinforcing sheet or a base material layer coated with a thermoplastic resin is prepared, and a skin, a reinforcing sheet, a base material layer, a reinforcing sheet, and a release paper are stacked, and heat is applied. A plate-shaped laminated body is prepared by pressing. Then, when necessary, this laminate is preheated, a cold press method of press molding with a press mold at room temperature, a reinforcing sheet or a base material layer coated with a thermosetting resin is prepared, and a skin, A hot pressing method is known in which a reinforcing sheet, a base material layer, a reinforcing sheet, and a release liner are stacked and pressure-molded with a heated press mold. It is also known to insert a film between the surface skin and the reinforcing layer in order to prevent permeability. An example of such a molded ceiling is, for example, Japanese Patent Laid-Open No. 08-2
46315, JP-A-09-277415,
The one disclosed in JP-A-10-000716 is known.

【０００３】[0003]

【発明が解決しようとする課題】上記のような従来技術
において補強材として使用されるガラス繊維は、補強効
果が極めて優れており、成形寸法の安定性が良いので、
車両用等の成形内装材として広く使用されている。しか
し、ガラス繊維は有用な半面、問題点も有している。す
なわち、製品成形時に発生する成形端末を処分する、或
は使用済み製品を処理するために焼却した際に、極微量
の砒素が発生するため、環境問題上の課題を抱えてい
る。The glass fiber used as a reinforcing material in the above-mentioned prior art has an extremely excellent reinforcing effect and has good stability of molding dimension.
It is widely used as a molded interior material for vehicles. However, glass fibers are useful but also have problems. That is, when a molding terminal generated during product molding is disposed of or when a used product is incinerated for processing, a very small amount of arsenic is generated, which poses an environmental problem.

【０００４】[0004]

【課題を解決するための手段】一方、ガラス繊維を使わ
ないものも知られている。例えば、麻を撚り合わせた繊
維を２〜３ｍｍのかなり荒い目で織り、この織物を補強
材として使用した例があるが（Opel：ベクトラ他）、織
物を補強材として使った場合伸び縮みが不自由な為、絞
り成形部分でしわが発生する。また撚り合わせた繊維で
は接着剤が中まで含浸しにくい為、硬化が不十分で表面
に凹凸が発生しやすい。[Means for Solving the Problems] On the other hand, there is also known one which does not use glass fiber. For example, there is an example in which hemp-twisted fibers are woven with a fairly coarse mesh of 2 to 3 mm and this woven fabric is used as a reinforcing material (Opel: Vectra et al.). Since it is free, wrinkles occur at the draw-formed part. In addition, the twisted fibers are less likely to be impregnated with the adhesive to the inside, so curing is insufficient and unevenness is likely to occur on the surface.

【０００５】また、特開２００１−０４７５４４号公報
では、麻、ケナフ、サイザル繊維、竹繊維、木質繊維の
植物繊維を分岐切断或は粉砕したものをガラス繊維の代
わりに使用することが開示されている。この公報のもの
では、補強層が植物繊維であるので、処分時に焼却した
際に環境問題を生じない点でガラス繊維に比べて優れて
いる。しかし、植物繊維の吸湿時の伸縮或は剛性低下に
より、成形内装材が使用中に変形する問題を生じること
が判明した。特に、成形天井や成形トリム等のように３
次元的に立体的成形したものでは、伸縮・剛性低下等の
要因で大きく変形して製品として使用できないものが発
生した。即ちガラス繊維を植物繊維に置き換えただけで
は、補強層としての機能で不十分であった。Further, Japanese Patent Laid-Open No. 2001-047544 discloses that plant fibers such as hemp, kenaf, sisal fiber, bamboo fiber, and wood fiber are branched and cut or crushed and used in place of glass fiber. There is. According to this publication, since the reinforcing layer is a plant fiber, it is superior to glass fiber in that environmental problems do not occur when incinerated at the time of disposal. However, it has been found that the molded interior material is deformed during use due to expansion or contraction of the plant fiber when it absorbs moisture or a decrease in rigidity. Especially for molded ceilings, molded trims, etc.
Some three-dimensionally molded products were greatly deformed due to factors such as expansion and contraction and reduced rigidity, and some of them could not be used as products. That is, merely replacing the glass fiber with the plant fiber was not sufficient as the function as the reinforcing layer.

【０００６】そこで本願の発明者は、植物繊維の利点を
生かしつつ、補強層の補強不足、即ち耐変形性を補うた
めの手法について種々検討を行った。その結果、植物繊
維と補強繊維との混合体とすると良いことを見いだし
た。[0006] Therefore, the inventor of the present application has conducted various studies on a technique for supplementing the insufficient reinforcement of the reinforcing layer, that is, the deformation resistance while making the most of the advantage of the plant fiber. As a result, they have found that it is preferable to use a mixture of plant fibers and reinforcing fibers.

【０００７】具体的には、請求項１の発明は、硬質発泡
体を有する基材層と、該基材層に接合された表皮層と、
該基材層と該表皮層との間に挟まれた補強層とを有する
成形内装材において、該補強層が植物繊維と補強繊維と
の混合体からなる構成である。この構成では、植物繊維
が吸湿して伸縮することを補強繊維で抑制できるので、
成形内装材の耐変形性を大幅に向上できる。[0007] Specifically, the invention of claim 1 comprises a base material layer having a hard foam, and a skin layer joined to the base material layer.
In a molded interior material having a reinforcing layer sandwiched between the base material layer and the skin layer, the reinforcing layer is composed of a mixture of plant fibers and reinforcing fibers. In this configuration, since the reinforcing fibers can suppress the plant fibers from absorbing moisture and expanding and contracting,
The deformation resistance of the molded interior material can be greatly improved.

【０００８】請求項２の発明は、請求項１に記載の成形
内装材において、該補強繊維が無機繊維からなるので、
植物繊維が吸湿して伸縮することを補強繊維で効果的に
抑制できる。According to a second aspect of the present invention, in the molded interior material according to the first aspect, since the reinforcing fibers are inorganic fibers,
The reinforcing fibers can effectively prevent the plant fibers from absorbing moisture and expanding and contracting.

【０００９】請求項３の発明は、請求項２に記載の成形
内装材において、該補強繊維がカーボン繊維からなるの
で、植物繊維が吸湿して伸縮することをこのカーボン繊
維で効果的に抑制できるとともに、植物繊維とこのカー
ボン繊維との混合体を焼却処分した際に、有害成分の発
生が無く、環境問題を起こさない。According to a third aspect of the invention, in the molded interior material according to the second aspect, since the reinforcing fiber is made of carbon fiber, it is possible to effectively suppress the plant fiber from absorbing moisture and expanding and contracting. At the same time, when a mixture of plant fiber and this carbon fiber is incinerated, no harmful components are generated and environmental problems do not occur.

【００１０】請求項４の発明は、請求項３に記載の成形
内装材において、該カーボン繊維が繊維束からなるの
で、高強度であり、少ない量で植物繊維の伸縮を抑制で
き、コストダウンできる。According to a fourth aspect of the invention, in the molded interior material according to the third aspect, since the carbon fibers are fiber bundles, the strength is high, the expansion and contraction of the plant fibers can be suppressed with a small amount, and the cost can be reduced. .

【００１１】請求項５の発明は、請求項1ないし４のい
ずれかに記載の成形内装材において、該植物繊維が麻
材、ケナフ、木質繊維、サボテン繊維、サトウキビ繊維
の少なくとも１種からなるので、自然の素材であり焼却
処分時の有害成分の発生が無く、また、低コストで入手
できる。According to the invention of claim 5, in the molded interior material according to any one of claims 1 to 4, the plant fiber comprises at least one kind of hemp, kenaf, wood fiber, cactus fiber and sugar cane fiber. Since it is a natural material, no harmful components are generated during incineration, and it is available at low cost.

【００１２】請求項６の発明は、請求項１ないし４のい
ずれかに記載の成形内装材において、該植物繊維がサイ
ザル繊維からなる構成である。このサイザル繊維は、自
然の素材であり焼却処分時の有害成分の発生が無い。ま
た、サイザル繊維は、既にロープや麻袋等の原料として
使用されている材料であり、容易に且つ低コストで入手
できる。また、車両用の成形天井等のように多量に使用
する際にも、安定した品質で所定量確保でき、好適であ
る。According to a sixth aspect of the present invention, in the molded interior material according to any of the first to fourth aspects, the plant fibers are sisal fibers. This sisal fiber is a natural material and does not generate harmful components when incinerated. Sisal fiber is a material already used as a raw material for ropes, hemp bags, etc., and can be easily obtained at low cost. Further, even when used in a large amount such as a molded ceiling for a vehicle, a predetermined amount can be secured with stable quality, which is preferable.

【００１３】請求項７の発明は、請求項1ないし６のい
ずれかに記載の成形内装材において、該植物繊維と該補
強繊維との重量割合は、該植物繊維：３０〜７０％に対
して、補強繊維：７０〜３０％であるので、植物繊維が
吸湿して伸縮するのを効果的に抑制できる。植物繊維が
３０％以下、即ち補強繊維が７０％以上になると、植物
繊維が少なくなり、剛性が不足するとともに、コストア
ップとなり実用的でなくなる。また、基材層及び表皮層
との接合強度が低下し、接合力を高める手段を講じる必
要がある。植物繊維が７０％以上、即ち補強繊維が３０
％以下になると、補強繊維が少なくて、植物繊維の伸縮
を抑制する効果に劣り、成形内装材としての使用に耐え
られるものが得られない。したがって、植物繊維と補強
繊維との重量割合は、上記範囲にすることが好ましい。
特に、植物繊維：４０〜６０で補強繊維：６０〜４０と
することが、更に好ましい。The invention according to claim 7 is the molded interior material according to any one of claims 1 to 6, wherein the weight ratio of the plant fiber and the reinforcing fiber is 30 to 70% of the plant fiber. Reinforcing fiber: Since it is 70 to 30%, it is possible to effectively suppress the plant fiber from absorbing moisture and expanding and contracting. When the plant fiber content is 30% or less, that is, when the reinforcing fiber content is 70% or more, the plant fiber content is reduced, the rigidity is insufficient, and the cost is increased, which is not practical. Further, the bonding strength between the base material layer and the skin layer is lowered, and it is necessary to take measures to increase the bonding strength. 70% or more of plant fibers, that is, 30 reinforcing fibers
When the content is less than 100%, the reinforcing fibers are small and the effect of suppressing the expansion and contraction of the plant fibers is poor, and a product which can be used as a molded interior material cannot be obtained. Therefore, the weight ratio of the plant fiber and the reinforcing fiber is preferably within the above range.
In particular, it is more preferable to use plant fibers of 40 to 60 and reinforcing fibers of 60 to 40.

【００１４】請求項８の発明は、請求項1ないし７のい
ずれかに記載の成形内装材において、該補強層は該植物
繊維と該補強繊維とが積層方向に混在して成形された格
子状のシート材からなるので、植物繊維と補強繊維とが
積層方向に重なり合って配設される。即ち、ある部分の
断面を見るとカーボン繊維を挟んでその両側に植物繊維
が存在したり、別の断面を見ると植物繊維を挟んでその
両側にカーボン繊維が存在したりする状態であり、カー
ボン繊維が効果的に植物繊維の伸縮を抑制することがで
きる。特に少ないカーボン量で植物繊維の伸縮を抑制で
きる。The invention according to claim 8 is the molded interior material according to any one of claims 1 to 7, wherein the reinforcing layer is formed by mixing the plant fiber and the reinforcing fiber in the laminating direction. Since it is made of the sheet material, the plant fiber and the reinforcing fiber are arranged so as to overlap each other in the stacking direction. That is, when a cross section of a certain part is seen, plant fibers are present on both sides of the carbon fiber, and when a different cross section is seen, plant fibers are sandwiched and carbon fibers are present on both sides of the carbon fiber. The fiber can effectively suppress the expansion and contraction of the plant fiber. The expansion and contraction of plant fibers can be suppressed with a particularly small amount of carbon.

【００１５】請求項９の発明は、請求項1ないし７のい
ずれかに記載の成形内装材において、該補強層は該植物
繊維の格子状シート材と該補強繊維の格子状シート材と
が互いに積層された混合体からなるので、補強繊維の必
要量を制御することが容易である。例えば、成形内装材
の特に変形しやすい部分や変形が問題となる部分に多く
補強繊維を配設するようにする際に、その部分にカーボ
ン繊維の多いシートや、カーボン繊維シートを重ねて配
設する等の対応で可能であり、製造作業が容易である。
又、カーボン繊維のシートを間に挟んで、その両側に植
物繊維のシート重ね、基材層及び表皮層と接合するよう
にすることで、植物繊維と両層との接着容易性により、
接着強度を確保できる。A ninth aspect of the present invention is the molded interior material according to any one of the first to seventh aspects, wherein in the reinforcing layer, the lattice-like sheet material of the plant fiber and the lattice-like sheet material of the reinforcing fiber are mutually formed. Being composed of a laminated mixture, it is easy to control the required amount of reinforcing fibers. For example, when arranging a large amount of reinforcing fibers in a particularly easily deformable portion of a molded interior material or in a portion where deformation is a problem, a sheet with a large amount of carbon fibers or a carbon fiber sheet should be placed over the portion. It is possible to cope with the situation, and the manufacturing work is easy.
Also, by sandwiching a sheet of carbon fiber between the sheets of vegetable fiber on both sides, by joining the base material layer and the epidermis layer, due to the easy adhesion of the plant fiber and both layers,
Adhesive strength can be secured.

【００１６】請求項１０の発明は、請求項1ないし９の
いずれかに記載の成形内装材において、該植物繊維が直
径１．０ｍｍ以下で、長さが１０〜１００ｍｍである。
この際の直径とは、断面円形以外の場合には径の短いほ
うの長さであって、直径１．０ｍｍを超えると、成形品
表面に繊維の凹凸が現れ外観を著しく損なうので、好ま
しくない。直径０．５ｍｍ以下のものが更に好ましい。
長さは１０ｍｍ以下では要求される補強効果が得られ
ず、逆に繊維が１００ｍｍよりも長すぎると、互いに絡
まって均一に分散できない。更には、３０ｍｍ〜５０ｍ
ｍのものが好ましい。なお長さは全て均一な長さのもの
に揃える必要はなく、上記範囲の長さのものであれば、
異なった長さのものでも良い。A tenth aspect of the present invention is the molded interior material according to any one of the first to ninth aspects, wherein the plant fiber has a diameter of 1.0 mm or less and a length of 10 to 100 mm.
The diameter at this time is the length of the shorter diameter in the case of a shape other than a circular cross section, and if the diameter exceeds 1.0 mm, irregularities of fibers appear on the surface of the molded product and the appearance is significantly impaired, which is not preferable. . A diameter of 0.5 mm or less is more preferable.
If the length is 10 mm or less, the required reinforcing effect cannot be obtained, and conversely, if the fibers are longer than 100 mm, they are entangled with each other and cannot be uniformly dispersed. Furthermore, 30mm-50m
m is preferable. Note that it is not necessary to align all the lengths with a uniform length, and if the length is within the above range,
Different lengths may be used.

【００１７】請求項１１の発明は、請求項1ないし１０
のいずれかに記載の成形内装材において、該補強繊維が
直径１．０ｍｍ以下で、長さが１０〜１００ｍｍであ
る。この請求項１１も請求項１０と同様なことが言え
る。The invention of claim 11 relates to claims 1 to 10.
In the molded interior material according to any one of 1 to 3, the reinforcing fiber has a diameter of 1.0 mm or less and a length of 10 to 100 mm. The same can be said for claim 11 as for claim 10.

【００１８】請求項１２の発明は、請求項１ないし１１
のいずれかに記載の成形内装材において、該基材層が硬
質ウレタンフォームであるので、成形内装材として、安
定した寸法、安定した成形性のものが得られる。The twelfth aspect of the present invention includes the first to eleventh aspects.
In the molded interior material according to any one of 1 to 3, since the base material layer is a rigid urethane foam, a molded interior material having stable dimensions and stable moldability can be obtained.

【００１９】請求項１３の発明は、請求項１ないし１２
のいずれかに記載の成形内装材において、該混合体が該
基材層の両面に接合されているので、一方に表皮層を設
け、他方に離型シートを接合したものとして用意するこ
とができる。このようにして用意したものを、離型シー
トを分離して所定の面に貼り付けることで、成形した内
装材を必要とするところに簡単に設置することができ
る。The invention of claim 13 is based on claim 1
In the molded interior material according to any one of 1 to 3, since the mixture is bonded to both surfaces of the base material layer, it can be prepared by providing a skin layer on one side and a release sheet on the other side. . By separating the release sheet and sticking it to a predetermined surface, the thus prepared one can be easily installed in a place where the molded interior material is required.

【００２０】請求項１４の発明は、請求項１ないし１３
のいずれかに記載の成形内装材において、該成形内装材
が車両の成形天井であり、成形天井として実用的なもの
が得られる。特に、車両のリサイクルや処分時にこの成
形天井を焼却処分しても、有害成分を発生しないので、
環境問題上からも、優れている。The invention of claim 14 relates to claims 1 to 13.
In the molded interior material according to any one of 1 to 3, the molded interior material is a molded ceiling of a vehicle, and a practical molded ceiling is obtained. In particular, even if this molded ceiling is incinerated when recycling or disposing of the vehicle, no harmful components are generated, so
It is also excellent in terms of environmental issues.

【００２１】請求項１５の発明は、請求項１ないし１４
のいずれかに記載の成形内装材において、該混合体を該
基材層及び表皮層に接合する熱硬化型接着剤が該補強層
に含有されているので、基材層、補強層及び表皮層を重
ねて熱プレスすることで、互いに接合され、成形された
ものを得られ、生産性に優れる。The fifteenth aspect of the invention is the first to fourteenth aspects.
In the molded interior material according to any one of items 1 to 5, since the thermosetting adhesive that bonds the mixture to the base material layer and the skin layer is contained in the reinforcement layer, the base material layer, the reinforcement layer, and the skin layer. By stacking and hot pressing, it is possible to obtain molded products that are bonded to each other and have excellent productivity.

【００２２】請求項１６の発明は、成形内装材の製造方
法であって、硬質発泡体のシート状基材を用意し、該シ
ート状基材に接着される混合体を用意し、該混合体は植
物繊維と補強繊維とが混在し、バインダーでシート状に
形成されており、該混合体を介して該シート状基材に接
着される表皮材を用意し、該混合体、シート状基材及び
表皮を互いに接着する接着剤を該混合体に塗布し、上記
のように用意した該シート状基材、該混合体及び該表皮
材材を重ねて成形型内に配置し、加圧接着及び成形する
構成である。この成形内装材の製造方法によれば、混合
体の取り扱いが容易であり、生産性に優れる。A sixteenth aspect of the present invention is a method for producing a molded interior material, comprising preparing a sheet-like base material of a rigid foam, preparing a mixture adhered to the sheet-like base material, and preparing the mixture. Is a mixture of plant fibers and reinforcing fibers, is formed into a sheet with a binder, and prepares a skin material that is bonded to the sheet-shaped substrate through the mixture. And an adhesive for adhering the skins to each other is applied to the mixture, and the sheet-shaped substrate prepared as described above, the mixture and the skin material are placed in a molding die, and pressure-bonded and It is a configuration for molding. According to this method for producing a molded interior material, the mixture is easy to handle and has excellent productivity.

【００２３】請求項１７の発明は、成形内装材の製造方
法であって、硬質発泡体のシート状基材を用意し、該シ
ート状基材に接着される混合体を用意し、該混合体は植
物繊維と補強繊維とが混在し、通気性を備えた網目状の
シート形状に形成されており、該混合体を介して該シー
ト状基材に接着される表皮材及び離面紙を用意し、該混
合体、シート状基材及び表皮材を互いに接着する接着剤
を該混合体に塗布し、上記のように用意した該シート状
基材、該混合体、該表皮材及び該離面紙を、離面紙、混
合体、シート状基材、混合体及び表皮材の順に重ねて成
形型内に配置し、加圧接着及び成形する構成である。こ
の成形内装材の製造方法によれば、混合体の取り扱いが
容易であり、生産性に優れる。その上、混合体が通気性
を備えるので、基材ウレタンの発泡空間を消音空間とし
て利用でき、消音機能に優れた成形内装品が得られる。The invention of claim 17 is a method for producing a molded interior material, which comprises preparing a sheet-like base material of a rigid foam, preparing a mixture to be adhered to the sheet-like base material, and preparing the mixture. Is a mixture of plant fibers and reinforcing fibers, and is formed into a mesh-like sheet having air permeability. Prepare a skin material and a release paper that are bonded to the sheet-shaped substrate through the mixture. Then, an adhesive agent for adhering the mixture, the sheet-shaped substrate and the skin material to each other is applied to the mixture, and the sheet-shaped substrate, the mixture, the skin material and the release surface prepared as described above. In this configuration, the release paper, the mixture, the sheet-shaped substrate, the mixture, and the skin material are stacked in this order in the molding die and pressure-bonded and molded. According to this method for producing a molded interior material, the mixture is easy to handle and has excellent productivity. In addition, since the mixture has air permeability, the foaming space of the urethane base material can be used as a sound deadening space, and a molded interior product having an excellent sound deadening function can be obtained.

【００２４】本発明の植物繊維としては、セルロースを
主体とした植物を分岐切断または粉砕したものであっ
て、麻、ケナフ、サイザル繊維、竹繊維、木質繊維が挙
げられる。木質繊維は木から得られる。木としては、
杉、松、けやき、ひのき、ひば、桜、ポプラ、樅などが
挙げられる。特にサイザル繊維が生産性、コスト等から
好ましい。植物繊維は、ウレタンフォーム層の上下に、
６０〜３００ｇ／ｍ2、例えば１００〜２００ｇ／ｍ2に
補強材として均一に分布されるようにすることが好まし
い。植物繊維は直径１．０ｍｍ以下（例えば０．２〜
０．８ｍｍ）且つ長さ１０〜１００ｍｍ（例えば３０〜
５０ｍｍ）の間に寸法調整されたものが好ましい。この
場合、繊維断面の短い長さのほうの長さを直径とした。
この直径が１．０ｍｍを超す繊維を補強材として使用す
ると、成形品表面に繊維の凹凸が現れ外観を著しく損な
う。これらの繊維は簡単な設備で１０〜１００ｍｍの長
さに切断出来る。長さが１０ｍｍ以下では要求される補
強効果が得られず、逆に繊維が長すぎると、互いに絡ま
って均一にフォーム上に分散できない。自動車天井材の
ような大きな面積の成形品にも比較的簡単にかつ均一に
散布でき、かつ充分な補強効果を得る為には１０〜１０
０ｍｍの寸法が好ましい。The plant fiber of the present invention is obtained by branching or crushing a plant mainly composed of cellulose, and includes hemp, kenaf, sisal fiber, bamboo fiber and wood fiber. Wood fiber is obtained from wood. As a tree,
Examples include cedar, pine, zelkova, cypress, hiba, cherry blossoms, poplar, and fir tree. Particularly, sisal fiber is preferable in terms of productivity, cost and the like. The vegetable fibers are above and below the urethane foam layer,
It is preferable that the reinforcing material is uniformly distributed at 60 to 300 g / m 2 , for example, 100 to 200 g / m 2 . The plant fiber has a diameter of 1.0 mm or less (for example, 0.2 to
0.8 mm) and a length of 10 to 100 mm (for example, 30 to
It is preferably dimensioned between 50 mm). In this case, the shorter length of the fiber cross section was defined as the diameter.
If fibers having a diameter of more than 1.0 mm are used as a reinforcing material, irregularities of fibers appear on the surface of the molded product and the appearance is significantly impaired. These fibers can be cut to a length of 10 to 100 mm with simple equipment. If the length is 10 mm or less, the required reinforcing effect cannot be obtained. On the contrary, if the fibers are too long, they are entangled with each other and cannot be uniformly dispersed on the foam. In order to obtain a sufficient reinforcing effect, it is possible to disperse relatively easily and evenly on a molded product having a large area such as an automobile ceiling material.
A dimension of 0 mm is preferred.

【００２５】補強繊維も植物繊維と同様に、直径は１．
０ｍｍ以下であり、長さは１０ｍｍ〜１００ｍｍのもの
を使用することが好ましい。補強繊維は、それ自身が吸
湿及び／又は乾燥状態で伸縮せず、植物繊維の伸縮を抑
制するものである。その上、焼却処分時に有害成分を発
生しないものが使用される。例えば、無機繊維、セラミ
ック繊維が好適であり、特にカーボン繊維は、それ自身
が吸湿及び／又は乾燥で伸縮せず、植物繊維の伸縮を抑
制するとともに、焼却時に無公害であり、特に好まし
い。The reinforcing fiber has a diameter of 1.
It is preferably 0 mm or less and the length is preferably 10 mm to 100 mm. The reinforcing fiber itself does not expand and contract in a moisture-absorbed and / or dry state, and suppresses expansion and contraction of the plant fiber. In addition, those that do not generate harmful components when incinerated are used. For example, inorganic fibers and ceramic fibers are preferable, and carbon fibers are particularly preferable because they themselves do not expand or contract due to moisture absorption and / or drying, suppress expansion and contraction of plant fibers, and cause no pollution during incineration.

【００２６】基材層は硬質ウレタンフォームが好まし
い。ウレタンフォームは、シート状であってよく、その
厚さは用途によって異なるが、成形天井の場合には通常
３〜１０ｍｍのものが使用される。熱硬化型接着剤は、
芳香族ポリイソシアネート、水、触媒、必要に応じてポ
リオールからなる接着剤である。熱硬化型接着剤として
は、上記特開２００１−０４７５４４号公報に記載され
たものや、通常に使用されている接着剤が使用できる。
熱硬化型接着剤の量は、１００ｇ／ｍ2の補強層用のマ
ット材に対して、１０〜１５０ｇ／ｍ2の接着剤、好ま
しくは１５〜７０ｇ／ｍ2の接着剤を塗布して使用され
る。更に、好ましくは、１５〜４０ｇ／ｍ2である。１
５ｇ／ｍ2以下、特に１０ｇ／ｍ2以下では、接着剤の量
が不十分であり、１５０ｇ／ｍ2以上になると接着剤が
多すぎて、取り扱いが難しくなる。特に４０ｇ/ｍ2以下
であれば、余分な接着剤のはみ出しが無く、取り扱いが
容易であり、接着剤はみ出し防止用のフイルムを設けな
くても良いメリットを有する。The base material layer is preferably a rigid urethane foam. The urethane foam may be in the form of a sheet, and the thickness thereof varies depending on the application, but in the case of a molded ceiling, one having a thickness of 3 to 10 mm is usually used. The thermosetting adhesive is
It is an adhesive composed of an aromatic polyisocyanate, water, a catalyst, and optionally a polyol. As the thermosetting adhesive, the adhesive described in JP 2001-047544 A or an adhesive that is normally used can be used.
The amount of thermosetting adhesive agent with respect to the mat material for the reinforcing layer of 100 g / m 2, the adhesive of 10 to 150 g / m 2, preferably by applying an adhesive 15~70g / m 2 using To be done. Furthermore, it is preferably 15 to 40 g / m 2 . 1
If it is 5 g / m 2 or less, especially 10 g / m 2 or less, the amount of the adhesive is insufficient, and if it is 150 g / m 2 or more, the amount of the adhesive is too large and the handling becomes difficult. In particular, when it is 40 g / m 2 or less, there is an advantage that there is no extra adhesive protruding and handling is easy, and it is not necessary to provide a film for preventing the adhesive protruding.

【００２７】必要に応じて、接着剤染み出し防止用フィ
ルムを、混合体と表皮層の間に設置してよい。表面装飾
用表皮としては、ポリオレフィン、ポリエステル、ポリ
アミド系の織布または不織布、ビニールレザーが挙げら
れる。If desired, an adhesive seepage prevention film may be placed between the mixture and the skin layer. Examples of the surface decoration surface skin include polyolefin, polyester, polyamide woven or non-woven fabric, and vinyl leather.

【００２８】製造方法としては、植物繊維と補強繊維と
の混合体に熱硬化型接着剤を塗布したシートを用意し、
ウレタンフォームの両面に重ね、更に表皮材を重ね配置
したものを、加熱した金型に入れて加圧成形するように
しても良い。また、ウレタンフォームの両面に、熱硬化
型接着剤を塗布（例えば、スプレー塗布）し、植物繊維
と補強繊維とを両面に散布し、表皮材を重ね配置したも
のを、加熱金型に入れ加圧し、接着剤を硬化させ、金型
から成形品を取り出す方法でも良い。As a manufacturing method, a sheet prepared by applying a thermosetting adhesive to a mixture of plant fibers and reinforcing fibers is prepared,
It is also possible to stack urethane foam on both sides, and further stack the skin material, and place it in a heated mold for pressure molding. Also, apply a thermosetting adhesive to both sides of the urethane foam (for example, spray application), sprinkle plant fibers and reinforcing fibers on both sides, and put the skin material overlaid and put it in the heating mold. A method of pressing, curing the adhesive, and taking out the molded product from the mold may be used.

【００２９】本発明の成形内装材は、自動車用成形内装
材、例えば自動車用成形天井材、成形ドアトリム、リヤ
パッケージトレイ、フロア材等に使用できる。自動車に
限らず、他の乗物にも適用可能である。成形天井材とし
て使用する際には、ウレタンフォームからできている層
の厚さは、３〜１０ｍｍ、植物繊維と熱硬化型接着剤か
らできている層の厚さは、０．２〜２ｍｍのものが使用
される。The molded interior material of the present invention can be used as a molded interior material for automobiles, for example, a molded ceiling material for automobiles, a molded door trim, a rear package tray, a floor material and the like. The invention is applicable not only to automobiles but also to other vehicles. When used as a molded ceiling material, the layer made of urethane foam has a thickness of 3 to 10 mm, and the layer made of plant fiber and a thermosetting adhesive has a thickness of 0.2 to 2 mm. Stuff used.

【００３０】[0030]

【発明の実施の形態】以下に本発明の実施例を示し、本
発明を具体的に説明する。図１は自動車の成形天井の斜
視図を示し、図２は図１の部分断面図を示す。図３は植
物繊維と補強繊維とを混在させて形成したシートの部分
図を示す。図１に示すように、成形天井１は、中央が凹
んだ立体形状に形成される。成形天井１の断面は、図２
に示すように、基材層２の両側に補強層３、４が配設さ
れ、その外側一方に表皮層５、他方側に離型シート（離
型層）６が接着されている。この補強層３、４の部分図
を図３に示す。図３で黒い太い線のものがカーボン繊維
１１を示し、白っぽい細い線がサイザル繊維１２を示
す。このものでは、適当な長さに切断されたカーボン繊
維１１とサイザル繊維１２とがランダムに混在して、積
層方向に互いに重なりあって分散している。BEST MODE FOR CARRYING OUT THE INVENTION The present invention will be described in detail below with reference to Examples of the present invention. 1 shows a perspective view of a molded ceiling of an automobile, and FIG. 2 shows a partial sectional view of FIG. FIG. 3 shows a partial view of a sheet formed by mixing plant fibers and reinforcing fibers. As shown in FIG. 1, the molded ceiling 1 is formed in a three-dimensional shape with a recessed center. The cross section of the molded ceiling 1 is shown in FIG.
As shown in FIG. 3, the reinforcing layers 3 and 4 are disposed on both sides of the base material layer 2, the outer skin layer 5 is adhered to one of the outer sides thereof, and the release sheet (release layer) 6 is adhered to the other side thereof. A partial view of the reinforcing layers 3 and 4 is shown in FIG. In FIG. 3, the thick black line indicates the carbon fiber 11, and the whitish thin line indicates the sisal fiber 12. In this structure, the carbon fibers 11 and the sisal fibers 12 that have been cut to an appropriate length are randomly mixed and overlapped and dispersed in the stacking direction.

【００３１】次に、上記実施例に関わる成形内装材の製
造方法を説明する。単位面積重量２００ｇ／ｍ2の連続
気泡を有する熱成形可能な硬質ウレタンフォームシート
（１，２００ｍｍ×１，６００ｍｍ×厚さ５．５ｍｍ）
を容易する。直径０．５ｍｍ以下、長さ３０〜５０ｍｍ
のサイザル繊維とカーボン繊維とを約１００ｇ／ｍ2の
目付で均一に散布し、バインダ−で互いに接着した混合
体を用意した。このバインダーは、サイザル繊維とカー
ボン繊維とがバラバラにならなければ良いもので、少量
でよい。この混合体は、図３に示すように、サイザル繊
維とカーボン繊維が薄く網状に相互に接着され、積層方
向に大きな通気性を持っている。（図３において、紙面
の表裏方向に貫通して見える状態）そして、トリコット
製表皮及び離面紙を用意する。Next, a method of manufacturing the molded interior material according to the above embodiment will be described. Thermoformable hard urethane foam sheet (1,200 mm x 1,600 mm x thickness 5.5 mm) having open cells with a unit area weight of 200 g / m 2.
To facilitate. Diameter 0.5 mm or less, length 30-50 mm
The sisal fiber and the carbon fiber of Example 1 were evenly spread with a basis weight of about 100 g / m 2 , and a mixture was prepared by adhering them to each other with a binder. The binder may be a small amount as long as the sisal fiber and the carbon fiber are not separated from each other, and a small amount may be used. As shown in FIG. 3, this mixture has a sisal fiber and a carbon fiber thinly bonded to each other in a net shape, and has a large air permeability in the stacking direction. (In FIG. 3, a state of being seen through in the front and back direction of the paper surface) Then, a tricot skin and a release paper are prepared.

【００３２】次に、混合体、基材、表皮及び離面紙を接
合するために、混合体にイソシアネート系接着剤を塗布
する。混合体への接着剤の塗布は、混合体の網目の大き
さとあいまって、混合体が通気性を持った（向こうが見
える）状態を維持した量に制御され、この実施例では１
００ｇ／ｍ2の混合体に対して、３０ｇ／ｍ2とした。こ
の場合に、混合体が通気性を持ったとは、上記接着剤を
塗布した状態で通気性を確保できたものも良いが、塗布
時には通気性がほとんど無く、接着剤が硬化して混合
体、基材、表皮、離面紙が接着された後に通気性が確保
されるものも含む。こうして用意した混合体を硬質ウレ
タンフォームシートの両側に配設し、その外側にトリコ
ットの装飾用表皮及び離面紙を配置して、成形型内に表
皮−混合体−基材−混合体−裏面紙の順で配置されるよ
うにする。成形金型内で加圧成形するとともに、互いを
接着させる。成形接着後成形品を金型から取り出し、
幅：１，２００ｍｍ×１，６００ｍｍ、そして天井を形
成する全ての材料を含めた総厚が７．５ｍｍとなった成
形天井を製造した。Next, an isocyanate adhesive is applied to the mixture in order to bond the mixture, the substrate, the skin and the release liner. The application of the adhesive to the mixture was controlled to an amount that, in combination with the mesh size of the mixture, maintained the mixture breathable (visible beyond), in this example 1
Against a mixture of 00g / m 2, it was 30 g / m 2. In this case, if the mixture has air permeability, it is also preferable that the air permeability can be secured in the state where the adhesive is applied, but there is almost no air permeability at the time of application, and the adhesive is cured to give a mixture. It also includes a material whose air permeability is ensured after the base material, the skin, and the release paper are bonded. The mixture thus prepared is arranged on both sides of the rigid urethane foam sheet, and the outer skin for tricot decoration and the release paper are arranged on the outer side thereof, and the skin-mixture-base material-mixture-back surface in the molding die. Make sure they are placed in the order of the paper. Pressure molding is performed in a molding die, and they are adhered to each other. After molding and bonding, take out the molded product from the mold,
A molded ceiling having a width of 1,200 mm × 1,600 mm and a total thickness of 7.5 mm including all materials forming the ceiling was manufactured.

【００３３】上記実施例の製造方法では、植物繊維（即
ちサイザル繊維）と補強繊維（即ちカーボン繊維）との
混合体を予めバインダーによりシート状に成形している
ので、混合体への接着剤の塗布、成形型内への配置等で
の取り扱いが容易であり、生産性に優れる。また、混合
体が、網状に大きな通気性を持っている（向こうが見え
る）状態に構成されるので、接着剤をこの混合体に塗布
した際にも、接着剤が混合体の表裏や内部に充填され
る。したがって、少ない接着剤の量で、混合体、基材層
及び表皮を接着できる。さらに、混合体に加える接着剤
が少なくて良いので、混合体の通気性が残存でき、表皮
−基材間の通気性を、接着剤の膜で損なう(分離する)こ
となく確保できる。これにより、基材ウレタンの発泡空
間を消音空間として利用することが可能となる。In the manufacturing method of the above-mentioned embodiment, since the mixture of the plant fiber (that is, sisal fiber) and the reinforcing fiber (that is, carbon fiber) is preliminarily formed into a sheet with a binder, an adhesive agent to the mixture is formed. It is easy to handle by coating, placing it in the mold, etc., and has excellent productivity. In addition, since the mixture is configured to have a large net-like breathability (the other side can be seen), when the adhesive is applied to this mixture, the adhesive does not adhere to the front and back of the mixture or inside the mixture. Is filled. Therefore, the mixture, the base material layer and the skin can be adhered with a small amount of adhesive. Furthermore, since the amount of adhesive to be added to the mixture is small, the air permeability of the mixture can remain, and the air permeability between the skin and the base material can be secured without impairing (separating) with the adhesive film. This makes it possible to use the foaming space of the urethane base material as a sound deadening space.

【００３４】次にテスト状況を説明する。上記実施例で
得られた成形天井の周囲を固定して、高湿度雰囲気、低
温雰囲気、高温雰囲気に置いた場合の中央部分の垂れ下
がり度合を検査した。高湿度雰囲気としては、１００％
近くの湿度雰囲気に数時間放置する。その後、低温雰囲
気更に高温雰囲気に数時間晒した。このような雰囲気検
査を数サイクル繰り返した。その結果を図４に示す。図
４に示す表の縦軸は変形量を示し、変形量１が商品とし
て許容できる変形値を示す。横軸にサイクル数を示す。
本発明品Aはサイザル繊維とカーボン繊維とを５０：５
０で混紡したシートを使用した場合を示し、比較品Bは
サイザル繊維のみのシートを使用した場合を示す。繊維
の長さは３０〜５０ｍｍのものを使用した。成形品の厚
さはどちらも７．５ｍｍのものを使用した。表皮層はト
リコットを使用し、接着剤はポリイソシアネート系接着
剤を使用した。このテスト結果から解かるように、サイ
ザル繊維のみの比較品Ｂでは、１サイクルのテスト中に
既に許容変形量を超えてしまった。それに対して、本発
明品Ａ１では、３サイクル繰り返しても許容変形量を超
えずに、その約半分の値で落ち着いた。Next, the test situation will be described. The degree of sagging of the central portion when the surroundings of the molded ceiling obtained in the above examples were fixed and placed in a high humidity atmosphere, a low temperature atmosphere, or a high temperature atmosphere was examined. 100% for high humidity atmosphere
Leave in a humid atmosphere for several hours. Then, it was exposed to a low temperature atmosphere and a high temperature atmosphere for several hours. Such an atmosphere inspection was repeated for several cycles. The result is shown in FIG. The vertical axis of the table shown in FIG. 4 represents the amount of deformation, and the amount of deformation 1 represents the amount of deformation that is acceptable as a product. The horizontal axis shows the number of cycles.
The product A of the present invention contains sisal fiber and carbon fiber at 50: 5.
The case where the sheet mixed with 0 was used is shown, and the comparative product B shows the case where the sheet containing only sisal fiber is used. Fibers having a length of 30 to 50 mm were used. Both of the molded products had a thickness of 7.5 mm. A tricot was used as the skin layer, and a polyisocyanate-based adhesive was used as the adhesive. As can be seen from this test result, the comparative product B containing only sisal fiber already exceeded the allowable deformation amount during one cycle of the test. On the other hand, in the case of the product A1 of the invention, the allowable deformation amount was not exceeded even after repeating 3 cycles, and the value was settled at about half the value.

【００３５】更に別のテストを行った。５０ｍｍ幅の大
きさのテストピースを用意して、曲げ強度試験を行っ
た。その場合の比較例Ｃは従来のガラスマットを使用し
たものと、前のテストで使用したと同様なサイザル繊維
とカーボン繊維との混紡シートからなるものを本発明品
Ａ２として比較テストした。本発明品Ａ２：２０〜２６
Ｎ／５０ｍｍ比較品 Ｃ ：１５〜１８Ｎ／５０ｍｍこ
の結果のように、本発明の植物繊維と補強繊維との混合
体からなる補強層は、従来のガラスマットの補強層を設
けたものよりも強度がアップしている。したがって、サ
イザル繊維等の植物繊維が吸湿して剛性が低下しても、
補強繊維がその低下をカバーし、成形内装材としての変
形量を許容値以下に維持できるものと思われる。Another test was performed. A bending strength test was conducted by preparing a test piece having a width of 50 mm. In Comparative Example C in that case, a product using a conventional glass mat and a product made of the same mixed sheet of sisal fiber and carbon fiber as used in the previous test were compared and tested as the product A2 of the present invention. Invention product A2: 20 to 26
N / 50 mm Comparative product C: 15 to 18 N / 50 mm As shown by these results, the reinforcing layer made of the mixture of the plant fiber and the reinforcing fiber of the present invention is stronger than the conventional glass mat provided with the reinforcing layer. Is up. Therefore, even if the plant fiber such as sisal fiber absorbs moisture to reduce the rigidity,
It is considered that the reinforcing fibers cover the decrease, and the amount of deformation as the molded interior material can be maintained below the allowable value.

【００３６】なお、上記実施態様では、サイザル繊維と
カーボン繊維とが、積層方向に混在したものを使用した
が、この実施形態に限られるものではなく、カーボン繊
維のシートとサイザル繊維のシートを別々に用意して、
積層したものでも良い。また、サイザル繊維とカーボン
繊維とが混在したシートに、サイザル繊維シート及び／
又はカーボン繊維シートを積層しても良い。また、カー
ボン繊維は、成形内装品において、必ずしも均一に分散
して無くてもよく、変形が大きいと思われる箇所や変形
が目立つ部分等に集中して配設し、その他の部分はカー
ボン繊維を少なく或は省略して、コスト低減を図っても
良い。In the above embodiment, the sisal fiber and the carbon fiber are mixed in the laminating direction, but the present invention is not limited to this embodiment, and the carbon fiber sheet and the sisal fiber sheet are separately provided. Prepare for
It may be a laminate. In addition, a sisal fiber sheet and / or a sheet in which sisal fiber and carbon fiber are mixed is used.
Alternatively, carbon fiber sheets may be laminated. In addition, the carbon fibers do not necessarily need to be uniformly dispersed in the molded interior product, and are arranged in a concentrated manner at a portion where deformation is likely to occur or a portion where deformation is noticeable. The cost may be reduced by reducing or omitting it.

【００３７】[0037]

【発明の効果】本発明では、硬質発泡体を有する基材層
と、該基材層に接合された表皮層と、該基材層と該表皮
層との間に挟まれた補強層とを有する成形内装材におい
て、該補強層が植物繊維と補強繊維との混合体からなる
ので、植物繊維が吸湿して伸縮することを補強繊維で抑
制し、成形内装材の耐変形性を大幅に向上でき、成形内
装材として使用できるようになった。According to the present invention, a base layer having a rigid foam, a skin layer joined to the base layer, and a reinforcing layer sandwiched between the base layer and the skin layer are provided. In the molded interior material having, since the reinforcing layer is composed of a mixture of plant fibers and reinforcing fibers, the reinforcing fibers suppress the plant fibers from absorbing moisture and expanding and contracting, and the deformation resistance of the molded interior material is significantly improved. It can now be used as a molded interior material.

【００３８】特に、補強層が植物繊維とカーボン繊維か
らなるものでは、成形時の剛性が高く、植物繊維が吸湿
して伸縮又は剛性低下を招いても、成形品としての変形
量を許容範囲内に抑制でき、且つ使用後に焼却処分する
際には、有害成分を発生することがなく、環境問題を起
こす恐れがない。In particular, when the reinforcing layer is composed of plant fibers and carbon fibers, the rigidity during molding is high, and even if the plant fibers absorb moisture and cause expansion or contraction or decrease in rigidity, the amount of deformation as a molded product is within an allowable range. When used for incineration after use, no harmful components are generated, and there is no risk of causing environmental problems.

【図面の簡単な説明】[Brief description of drawings]

【図１】本発明の成形天井の斜視図を示す。FIG. 1 shows a perspective view of a molded ceiling of the present invention.

【図２】図１の成形天井の部分断面図を示す。2 shows a partial sectional view of the molded ceiling of FIG.

【図３】本発明の補強層の部分図を示す。FIG. 3 shows a partial view of a reinforcing layer of the present invention.

【図４】評価テストのグラフを示す。FIG. 4 shows a graph of an evaluation test.

【符号の説明】[Explanation of symbols]

１ 成形天井 ２ 基材層 ３ 補強層 ４ 補強層 ５ 表皮層 ６ 離型層 １１ カーボン繊維 １２ サイザル繊維 1 molded ceiling 2 Base material layer 3 Reinforcing layer 4 Reinforcement layer 5 epidermis 6 Release layer 11 carbon fiber 12 Sisal fiber

───────────────────────────────────────────────────── フロントページの続き Ｆターム(参考） 3D023 BA01 BB03 BB08 BC01 BD01 BD03 BE04 BE05 4F100 AA01B AA01D AD11B AD11D AJ02B AJ02D AK51A AT00C BA03 BA04 BA07 BA10A BA10C BA22 CB02 DC15B DC16B DG01B DG01D DG18B DG18D DJ01A EC182 EJ172 EJ912 GB33 JA20B JA20D JK12A YY00B YY00D    ─────────────────────────────────────────────────── ─── Continued front page    F term (reference) 3D023 BA01 BB03 BB08 BC01 BD01                       BD03 BE04 BE05                 4F100 AA01B AA01D AD11B AD11D                       AJ02B AJ02D AK51A AT00C                       BA03 BA04 BA07 BA10A                       BA10C BA22 CB02 DC15B                       DC16B DG01B DG01D DG18B                       DG18D DJ01A EC182 EJ172                       EJ912 GB33 JA20B JA20D                       JK12A YY00B YY00D

Claims (17)

【特許請求の範囲】[Claims] 【請求項１】 硬質発泡体を有する基材層と、該基材層
に接合された表皮層と、該基材層と該表皮層との間に挟
まれた補強層とを有する成形内装材において、該補強層
が植物繊維と補強繊維との混合体からなることを特徴と
する。1. A molded interior material having a base layer having a rigid foam, a skin layer joined to the base layer, and a reinforcing layer sandwiched between the base layer and the skin layer. In the above, the reinforcing layer is made of a mixture of plant fibers and reinforcing fibers. 【請求項２】 請求項１に記載の成形内装材において、
該補強繊維が無機繊維からなることを特徴とする。2. The molded interior material according to claim 1,
The reinforcing fiber is made of an inorganic fiber. 【請求項３】 請求項２に記載の成形内装材において、
該補強繊維がカーボン繊維からなることを特徴とする。3. The molded interior material according to claim 2,
The reinforcing fiber is made of carbon fiber. 【請求項４】 請求項３に記載の成形内装材において、
該カーボン繊維が繊維束からなることを特徴とする。4. The molded interior material according to claim 3,
The carbon fiber is composed of a fiber bundle. 【請求項５】 請求項1ないし４のいずれかに記載の成
形内装材において、該植物繊維が麻材、ケナフ、木質繊
維、サボテン繊維、サトウキビ繊維の少なくとも１種か
らなることを特徴とする。5. The molded interior material according to any one of claims 1 to 4, wherein the plant fiber is at least one kind of hemp, kenaf, wood fiber, cactus fiber and sugar cane fiber. 【請求項６】 請求項１ないし４のいずれかに記載の成
形内装材において、該植物繊維がサイザル繊維からなる
ことを特徴とする。6. The molded interior material according to any one of claims 1 to 4, wherein the plant fiber is sisal fiber. 【請求項７】 請求項1ないし６のいずれかに記載の成
形内装材において、該植物繊維と該補強繊維との重量割
合は、該植物繊維：３０〜７０％に対して、補強繊維：
７０〜３０％であることを特徴とする。7. The molded interior material according to claim 1, wherein the weight ratio of the plant fiber and the reinforcing fiber is 30 to 70% of the plant fiber and the reinforcing fiber:
It is characterized by being 70 to 30%. 【請求項８】 請求項1ないし７のいずれかに記載の成
形内装材において、該補強層は該植物繊維と該補強繊維
とが積層方向に混在して成形された格子状のシート材か
らなることを特徴とする。8. The molded interior material according to any one of claims 1 to 7, wherein the reinforcing layer is a lattice-shaped sheet material formed by mixing the plant fiber and the reinforcing fiber in the laminating direction. It is characterized by 【請求項９】 請求項1ないし７のいずれかに記載の成
形内装材において、該補強層は該植物繊維の格子状シー
ト材と該補強繊維の格子状シート材とが互いに積層され
た混合体からなることを特徴とする。9. The molded interior material according to any one of claims 1 to 7, wherein the reinforcing layer is a mixture in which a lattice sheet material of the plant fiber and a lattice sheet material of the reinforcing fiber are laminated on each other. It is characterized by consisting of. 【請求項１０】 請求項1ないし９のいずれかに記載の
成形内装材において、該植物繊維が直径１．０ｍｍ以下
で、長さが１０〜１００ｍｍであることを特徴とする。10. The molded interior material according to any one of claims 1 to 9, wherein the plant fiber has a diameter of 1.0 mm or less and a length of 10 to 100 mm. 【請求項１１】 請求項1ないし１０のいずれかに記載
の成形内装材において、該補強繊維が直径１．０ｍｍ以
下で、長さが１０〜１００ｍｍであることを特徴とす
る。11. The molded interior material according to any one of claims 1 to 10, wherein the reinforcing fiber has a diameter of 1.0 mm or less and a length of 10 to 100 mm. 【請求項１２】 請求項１ないし１１のいずれかに記載
の成形内装材において、該基材層が硬質ウレタンフォー
ムであることを特徴とする。12. The molded interior material according to any one of claims 1 to 11, wherein the base material layer is a hard urethane foam. 【請求項１３】 請求項１ないし１２のいずれかに記載
の成形内装材において、該混合体が該基材層の両面に接
合されていることを特徴とする。13. The molded interior material according to any one of claims 1 to 12, wherein the mixture is bonded to both surfaces of the base material layer. 【請求項１４】請求項１ないし１３のいずれかに記載の
成形内装材において、該成形内装材が車両の成形天井で
あることを特徴とする。14. A molded interior material according to any one of claims 1 to 13, wherein the molded interior material is a molded ceiling of a vehicle. 【請求項１５】 請求項１ないし１４のいずれかに記載
の成形内装材において、該混合体を該基材層及び表皮層
に接合する熱硬化型接着剤が該補強層に含有されている
ことを特徴とする。15. The molded interior material according to claim 1, wherein the reinforcing layer contains a thermosetting adhesive that bonds the mixture to the base material layer and the skin layer. Is characterized by. 【請求項１６】 成形内装材の製造方法であって、 硬質発泡体のシート状基材を用意し、 該シート状基材に接着される混合体を用意し、 該混合体は植物繊維と補強繊維とが混在し、バインダー
でシート状に形成されており、 該混合体を介して該シート状基材に接着される表皮材を
用意し、 該混合体、シート状基材及び表皮材を互いに接着する接
着剤を該混合体に塗布し、 上記のように用意した該シート状基材、該混合体及び該
表皮材を重ねて成形型内に配置し、加圧接着及び成形す
ることを特徴とする成形内装材の製造方法。16. A method for producing a molded interior material, comprising preparing a sheet-like base material of rigid foam, and preparing a mixture adhered to the sheet-like base material, wherein the mixture is reinforced with plant fibers. Prepare a skin material in which fibers are mixed and formed into a sheet with a binder, and that is adhered to the sheet-shaped base material through the mixture, and the mixture, the sheet-shaped base material and the skin material are mutually provided. An adhesive to be adhered is applied to the mixture, and the sheet-shaped substrate, the mixture, and the skin material prepared as described above are overlapped and placed in a molding die, and pressure-bonding and molding are performed. And a method for producing a molded interior material. 【請求項１７】 成形内装材の製造方法であって、 硬質発泡体のシート状基材を用意し、 該シート状基材に接着される混合体を用意し、 該混合体は植物繊維と補強繊維とが混在し、通気性を備
えた網目状のシート形状に形成されており、 該混合体を介して該シート状基材に接着される表皮材及
び離面紙を用意し、該混合体、シート状基材及び表皮材
を互いに接着する接着剤を該混合体に塗布し、 上記のように用意した該シート状基材、該混合体、該表
皮材及び該離面紙を、離面紙、混合体、シート状基材、
混合体及び表皮材の順に重ねて成形型内に配置し、加圧
接着及び成形することを特徴とする成形内装材の製造方
法。17. A method for producing a molded interior material, comprising preparing a sheet-like base material of a rigid foam, and preparing a mixture to be adhered to the sheet-like base material, the mixture comprising a plant fiber and a reinforcement. A mixture of fibers and a breathable mesh-like sheet is prepared, and a skin material and a release paper that are bonded to the sheet-shaped substrate through the mixture are prepared. An adhesive for adhering the sheet-shaped base material and the skin material to each other is applied to the mixture, and the sheet-shaped base material, the mixture, the skin material and the release paper prepared as described above are released. Paper, mixture, sheet substrate,
A method for producing a molded interior material, comprising stacking a mixture and a skin material in this order in a molding die, followed by pressure bonding and molding.
JP2002114916A 2002-04-17 2002-04-17 Molded interior material and its production method Pending JP2003305789A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
JP2002114916A JP2003305789A (en) 2002-04-17 2002-04-17 Molded interior material and its production method

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
JP2002114916A JP2003305789A (en) 2002-04-17 2002-04-17 Molded interior material and its production method

Publications (1)

Publication Number Publication Date
JP2003305789A true JP2003305789A (en) 2003-10-28

Family

ID=29396518

Family Applications (1)

Application Number Title Priority Date Filing Date
JP2002114916A Pending JP2003305789A (en) 2002-04-17 2002-04-17 Molded interior material and its production method

Country Status (1)

Country Link
JP (1) JP2003305789A (en)

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2006004077A1 (en) * 2004-07-02 2006-01-12 Toyota Jidosha Kabushiki Kaisha Interior material structure for vehicle
US7651964B2 (en) 2005-08-17 2010-01-26 Milliken & Company Fiber-containing composite and method for making the same
US7696112B2 (en) 2005-05-17 2010-04-13 Milliken & Company Non-woven material with barrier skin
US7825050B2 (en) 2006-12-22 2010-11-02 Milliken & Company VOC-absorbing nonwoven composites
JP2012051428A (en) * 2010-08-31 2012-03-15 Sekisui Chem Co Ltd Laminate for vehicle exterior material, method for manufacturing the same, and vehicle exterior material
ITUB20152502A1 (en) * 2015-07-24 2017-01-24 Luca Paolo Gnizio A carbon fiber fabric, especially for car interior linings.
CN115175964A (en) * 2019-07-12 2022-10-11 阿德里亚诺迪马蒂有限公司 Method for preparing a preparation based on a polyurethane and Opuntia Ficus lndica mucilage with application in the manufacture of artificial skin-like flexible coatings

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2006004077A1 (en) * 2004-07-02 2006-01-12 Toyota Jidosha Kabushiki Kaisha Interior material structure for vehicle
US7569947B2 (en) 2004-07-02 2009-08-04 Toyota Jidosha Kabushiki Kaisha Interior material structure for vehicle
US7696112B2 (en) 2005-05-17 2010-04-13 Milliken & Company Non-woven material with barrier skin
US7651964B2 (en) 2005-08-17 2010-01-26 Milliken & Company Fiber-containing composite and method for making the same
US7825050B2 (en) 2006-12-22 2010-11-02 Milliken & Company VOC-absorbing nonwoven composites
JP2012051428A (en) * 2010-08-31 2012-03-15 Sekisui Chem Co Ltd Laminate for vehicle exterior material, method for manufacturing the same, and vehicle exterior material
ITUB20152502A1 (en) * 2015-07-24 2017-01-24 Luca Paolo Gnizio A carbon fiber fabric, especially for car interior linings.
WO2017017545A1 (en) * 2015-07-24 2017-02-02 Gnizio Luca Paolo A carbon fibre fabric, in particular for interior upholstery for cars
CN115175964A (en) * 2019-07-12 2022-10-11 阿德里亚诺迪马蒂有限公司 Method for preparing a preparation based on a polyurethane and Opuntia Ficus lndica mucilage with application in the manufacture of artificial skin-like flexible coatings

Similar Documents

Publication Publication Date Title
US9776536B2 (en) Cargo management system including a vehicle load floor having a cellulose-based core with a cellular structure and made by a composite, compression molding process and having a wood grain finish
US10913233B2 (en) Structure with honeycomb core
US6204209B1 (en) Acoustical composite headliner
US6702914B2 (en) Method for fabricating non-fiberglass sound absorbing moldable thermoplastic structure
US8518312B2 (en) Lightweight, multi-layered structural composites using recycled landfill-bound scrap
US5049439A (en) Thermoformable article
US5866235A (en) All synthetic fiber interior trim substrate
US20170080675A1 (en) Composite structure exhibiting energy absorption and/or including a defect free surface
CA2743651A1 (en) Single press mold process for forming a finished light weight structural component
FR2672007A1 (en) MOLDABLE COMPOSITE PANEL.
US20030162461A1 (en) Process, composition and coating of laminate material
US20040235378A1 (en) Vehicle interior trim component of basalt fibers and thermosetting resin and method of manufacturing the same
EP1878568B1 (en) Roof liner and procedure for obtaining a roof liner for vehicles
JP2003305789A (en) Molded interior material and its production method
JP2006198964A (en) Molded ceiling material for vehicle and its manufacturing method
JP2002046545A (en) Vehicular molded ceiling material and its manufacturing method
JP2007331673A (en) Molded interior material for vehicle and its manufacturing method
JP2004090413A (en) Molded interior material and method for manufacturing it
JPH0218039A (en) Inner packaging composite base raw material and panel
EP1567391B1 (en) Laminated headliner assembly and method for forming a lightweight laminated headliner
JP4036701B2 (en) Molded interior material and manufacturing method thereof
JP4252354B2 (en) Molded interior material
JPH0218038A (en) Inner packaging composite panel base raw material and panel
US20100040860A1 (en) All-composite sheet glass panel for recreational vehicle exterior wall
JP3985225B2 (en) Method for manufacturing sound-absorbing lightweight interior material