JP2010120315A - Base material, and method of manufacturing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a light-weighted base material having sufficient rigidity. <P>SOLUTION: This porous base material manufactured by aggregating adjacently, collectively a large number of straw bodies 2, by cutting the adjacently aggregated straw bodies 2 at a prescribed length by a nichrome wire 3, and by fusing thermally cut opening edges of the adjacent straw bodies 2 to be bonded each other. The straw bodies 2 are integrated firmly to enhance the rigidity, when joining a plate body on both faces of the base material, to form a structural material. Both are joined further surely and firmly when an adhesive film is interposed between the base material and the plate body. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a base material that can be used for the ceiling, deck side, or flooring of a vehicle, and a method for manufacturing the same.

  Conventionally, hard urethane, glass fiber reinforced polypropylene (PP), carbon fiber reinforced PP, or Apiton plywood has been used as this type of substrate. In Patent Document 1, a substrate made of rigid polyurethane foam is used, and a glass fiber layer made of glass fiber and polyethylene powder is provided on both surfaces thereof, and the surface of the glass fiber layer is covered with an adhesive resin film. An interior material for a vehicle such as a ceiling material in which a material and a back material are joined is disclosed.

JP-A-10-286924

  However, the conventional base material still has a problem that the weight reduction is not sufficient, and in particular, due to its high rigidity, apitone plywood frequently used as a base material for vehicle flooring has a problem of resource depletion. .

  Therefore, the present invention solves such problems, and an object of the present invention is to provide a base material having a light weight and sufficient rigidity and a method for manufacturing the same.

  In order to solve the above-mentioned problems, the base material of the present invention is composed of a resin tube having a predetermined length and a plurality of adjacent aggregates, and the cut opening edges of the adjacent tubes are bonded to each other by heat fusion. It is said. Such a base material is lightweight because it becomes porous due to the use of a resin tube, and if the longitudinal direction of the resin tube is used as the thickness direction of the base material, many adjacent resin tubes Since the peripheral wall of the wall becomes a vertical wall and supports the load, it exhibits sufficient rigidity.

  As a resin material for such a resin tube, polypropylene (PP), polyethylene (PE), polyethylene terephthalate (PET), nylon, or the like can be used. The outer diameter, thickness, and length of the resin tube are appropriately selected depending on the required rigidity and application.

  As the resin tube, a commercially available or ordered straw body can be used. Thereby, since the resin tube can be obtained at a low cost, the manufacturing cost of the base material can be reduced.

  If a face material is joined to both surfaces of the base material to form a structural material, the resin tubes are more firmly integrated and the rigidity is improved. Moreover, when an adhesive film is interposed between the base material and the face material, the bonding between the two can be further ensured and strengthened, and the rigidity is improved.

  The base material manufacturing method of the present invention comprises a plurality of resin tubes arranged adjacent to each other, the adjacently assembled tubes are thermally cut at a predetermined length, and the cut opening edges of the adjacent tubes are heat-sealed. It is characterized by obtaining a perforated base material.

  As described above, according to the base material of the present invention and the manufacturing method thereof, a base material having a light weight and sufficient rigidity can be obtained.

   FIG. 1 shows an example of a method for producing the substrate of the present invention. FIG. 1 shows a case where a rectangular flat plate base material is manufactured, and a container-like jig 1 having a U-shaped cross section opened upward is used. The jig 1 has an internal cross-sectional width W substantially equal to one side of the flat plate base material. A large number of straw bodies 2 as resin tubes are adjoined in the jig 1 as shown in the figure, and are laminated so that the end surfaces thereof are aligned and the shape thereof is a quadrangle substantially equal to the shape of the flat substrate. The straw body 2 can be a commercially available product or a custom-made product, and is manufactured by extrusion molding or the like.

  The both side walls 12 and 13 of the jig 1 are vertically moved from the inner bottom wall of the jig 1 in parallel with the end face at a position d away from the longitudinal end faces of the side walls 12 and 13 by a distance d equal to the thickness of the flat plate base material. Grooves 14 are formed which extend and open upward. Therefore, a known cutting machine used for cutting polystyrene foam or the like is prepared, and the nichrome wire 3 is energized to red heat it, and the red hot nichrome wire 3 is moved downward along the groove 14. As a result, the stacked straw bodies 2 are melted and cut at a fixed length d. Thereafter, when the entire laminated straw body 2 is pushed out from the end of the jig 1 in the longitudinal direction by an appropriate pushing tool, the laminated straw bodies 2 are cut between the opening edges of the adjacent straw bodies 2 at the time of melting and cutting. Are bonded and integrated with each other by heat fusion to obtain a perforated flat substrate 4 having a predetermined thickness d and predetermined plane dimensions V and W as shown in FIG.

Here, Table 1 shows the number of the straw bodies 2 necessary for obtaining the 1 m × 1 m square planar base material 4 calculated for different outer diameters of the straw bodies. In addition, as shown in FIG. 3, the arrangement | positioning of the straw body 2 in this case has shifted the position to the W direction orthogonal to V direction alternately. This arrangement is an example, and the present invention is not limited to this. Table 2 shows the necessity of the straw body 2 when the square planar base material 4 having different plate thicknesses of 1 m × 1 m is manufactured by using the straw body 2 made of polypropylene (PP) having different thicknesses and outer diameters. The number, the weight of each straw body 2, and the basis weight of the base material (weight per m ² ) are shown.

  Although the above-mentioned base material can be used by itself, as shown in FIG. 4, the face material 6 is joined directly to both surfaces of the base material 4 or with the adhesive film 5 interposed therebetween, and the straw bodies 2 are connected to each other. However, the structural material 7 can be integrated more firmly. Moreover, the base material 4 does not necessarily need to be a flat plate, For example, it can be set as the board | plate material which has a curved surface according to a use.

(First embodiment)
FIG. 5 shows an example in which an automobile ceiling interior material is realized by the structural material 7 including the base material 4 of the present invention. The base material 4 shown in FIG. 5 uses 6450 pieces / m ² of PP straw body 2 having an outer diameter of 13 mm and a wall thickness of 150 μm, and the straw body 2 is cut to a length of 5 mm to obtain a flat base material having the same thickness. . A chopped strand mat is joined to the upper and lower surfaces of the flat substrate 4 via the adhesive polyethylene (PE) film 51 as the face material 6 to form the structural material 7. Then, a blended mat is bonded to the surface (upper surface in the drawing) side of the structural material 7 as the skin adhesive layer 81, and the barrier film 82 and the spunbond nonwoven fabric 83 are bonded to the back surface of the structural material 7. The automobile ceiling interior material having such a structure can realize a basis weight of 450 to 600 g / m ² and exhibits light weight and sufficient rigidity as compared with those using hard urethane or the like.

(Second embodiment)
FIG. 6 shows an example in which the deck side interior material is realized by the structural material 7 including the base material 4 of the present invention. Since the base material 4 shown in FIG. 6 needs to have higher rigidity than that of the ceiling interior material, 13457 / m ² of PP straw bodies 2 having an outer diameter of 9 mm and a wall thickness of 150 μm are used. Is cut to a length of 5 mm to obtain a flat plate substrate having the same thickness. A glass fiber reinforced PP panel is bonded as a face material 6 to the upper and lower surfaces of the flat substrate 4 via an adhesive PE film 51 to form a structural material 7. Then, the barrier film 84 and the mixed cotton mat 85 are bonded to the front surface (upper surface in the drawing) side of the structural material 7 as the skin adhesive layer, and the adhesive film 86 and the nonwoven fabric 87 are bonded to the rear surface side of the structural material 7 as the back surface layer. . The deck side interior material having such a structure can realize a basis weight of 600 to 750 g / m ² , and is lighter and more sufficient than a conventional one using a single glass fiber reinforced PP or the like as a structural material. Exhibits excellent rigidity.

(Third embodiment)
In FIG. 7, the example which implement | achieved the bus floor material with the structural material 7 provided with the base material 4 of this invention is shown. Since the base material 4 of the bus floor material needs to be more rigid than the ceiling interior material and the deck side interior material, 13457 / m ² of PP straw bodies 2 having an outer diameter of 9 mm and a wall thickness of 200 μm are used. The straw body 2 is cut at a length of 15 mm to obtain a flat plate substrate having the same thickness. A glass fiber mat / thermosetting resin sheet as a face material 6 is joined to the upper and lower surfaces of the flat substrate 4 to form a structural material. The bath floor material having such a structure can realize a basis weight of 5000 to 6000 g / m ² , exhibits light weight and sufficient rigidity as compared with those using conventional apiton plywood, and has the effect of resource depletion. I do not receive it.

It is a perspective view which shows an example of the manufacturing method of this invention. It is a perspective view of a flat substrate. It is a top view which shows an example of arrangement | positioning of a straw body. It is a notional exploded sectional view of a structure. 1 is a conceptual exploded cross-sectional view of an automobile ceiling interior material using a substrate of the present invention. It is a notional exploded sectional view of the deck side interior material using the substrate of the present invention. It is a notional decomposition sectional view of the bus floor material using the substrate of the present invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Jig, 2 ... Straw body (resin tube), 3 ... Nichrome wire, 4 ... Base material, 5 ... Adhesive film, 6 ... Face material, 7 ... Structural material.

Claims (5)

A base material comprising a plurality of resin tubes of a predetermined length assembled adjacent to each other, and cut opening edges of the adjacent resin tubes are bonded to each other by heat fusion. The base material according to claim 1, wherein a straw body is used as the resin tube. A structural material obtained by further bonding a plate to both surfaces of the base material according to claim 1. The structural material according to claim 3, wherein an adhesive film is interposed between the substrate and the plate. A large number of resin tubes are gathered adjacent to each other, and the resin tubes gathered adjacent to each other are thermally cut at a predetermined length, and the cut opening edges of the adjacent resin tubes are heat-sealed to form a hole. A method for producing a base material, comprising obtaining the base material.

Images