JP2012153078A - Composite member, and method for manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a composite member and a method for manufacturing the same in which a woven or knitted fabric can be simply fixed to a base material and its designability is excellent.SOLUTION: The composite member includes a base material 1 composed of a first thermoplastic resin and a woven or knitted fabric 2 which covers the surface of the base material 1 and which part is fixed to the surface of the base material 1. The woven or knitted fabric 2 includes main fibers and fusion bonded parts composed of a second thermoplastic resin having a melting point lower than that of the main fiber, and the fusion bonded parts are woven or knitted with the main fibers or cover the main fibers. On the surface of the base material 1, a peripheral edge groove part 10 extending along at least a part of a peripheral edge part of the woven or knitted fabric 2 is formed. At least a part of the fusion bonded parts in the peripheral edge part of the woven or knitted fabric 2 is fusion bonded to the groove wall face of the peripheral edge groove part 10.

Description

  The present invention relates to a composite member and a method for producing the same, and more particularly to a composite member formed by fixing a woven or knitted fabric to a substrate surface.

  An interior member formed by fixing a woven or knitted fabric to a resin member is disposed in the interior of the automobile. For example, as shown in FIG. 11, as an interior member, there is a seat back member 90 disposed on the back surface of the seat and having a pocket portion 9. The seat back member 90 includes a seat back board 92, a net-like woven or knitted fabric 93, and a pressing plate 94. As shown in FIG. 12, the peripheral edge of the woven or knitted fabric 93 is folded back to the back side of the seat back board 92 and bonded to the back side. On the surface of the seat back board 92 on which the woven or knitted fabric 93 is disposed, a pressing plate 94 that presses the periphery of the seat back board 92 is disposed, and the pressing plate 94 and the seat back board 92 hold the woven or knitted fabric 93 therebetween. The holding plate 94 and the seat back board 92 are integrally fixed by heat caulking.

  However, in order to form the pocket portion 9 in the seat back member 90, three parts of the woven / knitted fabric 93, the seat back board 92, and the pressing plate 94 are used. For this reason, there were many parts. Further, the woven or knitted fabric 93 was disposed on the front surface of the seat back board 92, and its peripheral edge portion was folded back to be adhered to the back surface. For this reason, it took time and effort to attach the woven or knitted fabric 93 to the seat back board 92.

  Further, as shown in FIG. 13, it is proposed to form the pocket portion 9 by maintaining the appropriately expanded shape of the net 91 on the back surface of the seat and attaching the frame 98 formed by insert molding to the joint 91 a of the net 91. (Patent Document 1).

  However, it is necessary to design the frame 98 in accordance with the mesh structure of the net 91 so that the joint 91a of the net 91 is inserted. For this reason, the shape of the frame 98 is restricted, and the design freedom of the design of the pocket portion 9 is limited.

  In addition, as a vehicle interior member, a door trim or a console lid has been devised to improve design by fixing a woven or knitted fabric on the surface. For example, there are the following three methods for fixing the woven or knitted fabric to the interior member.

  In the first method, as shown in FIG. 14, a woven or knitted fabric 93 is attached to a sheet member 95 such as TPO or PVC, and after shaping into a shaped sheet 99, the shaped sheet 99 is This is a method of adhering to the surface of the interior member 98.

  In the second method, as shown in FIG. 15, in a state where the woven or knitted fabric 93 cut into a desired shape is arranged on the mold surface of the mold 96, resin is injected into the cavity 97 of the mold 96, and the interior member is removed. It is a method of forming.

  In the third method, as shown in FIG. 16, a woven or knitted fabric 93 is arranged along the split surface of the mold 96, and after clamping the mold, a resin is injected into the cavity 97 of the mold 96 to mold the interior member 98. In this method, the protruding portion of the woven or knitted fabric 93 protruding from the interior member 98 is cut.

  However, in the first method, it is necessary to shape the woven or knitted fabric 93 in advance with a mold or the like, which is troublesome. In the second method, when the resin material is injected with the woven or knitted fabric 93 placed in the cavity 97 of the mold 96, the woven or knitted fabric 93 is displaced from an accurate position by the flowing resin material, kinked, or wrinkled. There is a risk of In the third method, it is necessary to cut the protruding portion of the woven or knitted fabric 93 from the interior member 98 in a subsequent process, which requires extra man-hours. In any of the first to third methods, the entire back surface side of the woven or knitted fabric in the planar direction is fixed in a state of being buried in the interior member. For this reason, the woven or knitted fabric is visually recognized as a flat design, and the three-dimensional feeling inherent in the woven or knitted fabric is impaired.

JP 11-335953 A

  The inventor of the present application has earnestly constructed a structure that can produce a pocket portion by a simple method with a small number of parts, and can be fixed on the surface of the interior member with a simple manufacturing method and with the texture of the woven or knitted fabric remaining sufficiently. Explored.

  The present invention has been made in view of such circumstances, and an object of the present invention is to provide a composite member that can simply fix a woven or knitted fabric to a base material and has excellent design properties, and a method for manufacturing the same.

  (1) The composite member of the present invention is a composite member comprising a base material made of the first thermoplastic resin and a woven or knitted fabric that covers the surface of the base material and is partially fixed to the surface of the base material. The woven or knitted fabric includes a main fiber and a fusion part made of a second thermoplastic resin having a melting point lower than that of the main fiber, and the fusion part is woven and knitted together with the main fiber. Or is coated with the main fiber, and a peripheral groove portion extending along at least a part of the peripheral portion of the woven or knitted fabric is formed on the surface of the base material. At least a part of the fusion part is welded to a groove wall surface of the peripheral groove part.

  According to the said structure, a base material consists of a 1st thermoplastic resin, and a woven or knitted fabric is comprised from the main fiber and the melt | fusion part which consists of a 2nd thermoplastic resin whose melting | fusing point is lower than a main fiber. Yes. By placing this woven or knitted fabric on the surface of the substrate and pressing it against the peripheral groove formed on the substrate while heating, the peripheral portion of the woven or knitted fabric enters the peripheral groove. The fused portion of the portion that has entered the peripheral groove portion of the woven or knitted fabric is welded to the groove wall surface of the peripheral groove portion in a state where the main fiber is taken in. For this reason, the woven or knitted fabric is firmly bonded to the groove wall surface of the peripheral groove portion.

  Moreover, parts other than the peripheral part of a woven / knitted fabric have the general part which is not being fixed to the base material. The general part of the knitted or knitted fabric has a concavo-convex pattern formed on the woven or knitted fabric itself because the entire woven or knitted fabric appears on the substrate like a woven or knitted fabric that is only placed on the substrate. And the texture can be seen directly.

  Moreover, the general part which has not entered the peripheral groove portion of the woven or knitted fabric appears to be lifted with respect to the portion which has entered the peripheral groove portion of the woven or knitted fabric.

  Thus, the woven or knitted fabric looks three-dimensional as if it was raised on the surface of the base material while maintaining its own uneven pattern and texture. For this reason, the composite member of this invention is good-looking and is excellent in design property.

  Further, even when the peripheral edge of the woven or knitted fabric is frayed, the peripheral edge of the woven or knitted fabric is not conspicuous because the peripheral groove is formed in a concave shape. In addition, at the peripheral portion of the woven or knitted fabric, the fusing portion is welded to the groove wall surface in a state in which the main fiber is taken in, so that fraying of the main fiber can be prevented.

  Moreover, unevenness | corrugation is formed by joining to the peripheral groove part of a woven / knitted fabric. The uneven arrangement of the woven or knitted fabric can be freely changed by variously changing the arrangement of the peripheral groove portions formed on the surface of the substrate. Therefore, the degree of freedom in designing the unevenness of the woven or knitted fabric is high, and the design is excellent.

  Further, a gap is formed between the base material and the general part of the woven or knitted fabric. As will be described later, by forming an opening connected to the gap between the woven or knitted fabric and the base material, or by forming an opening in the woven or knitted fabric itself, the gap can be used as a pocket for storing small items. .

  Moreover, a composite member is produced by welding the fusion part which comprises a woven / knitted fabric to the peripheral groove part of a base material. For this reason, the number of parts is small and the number of man-hours can be reduced.

  Further, the woven or knitted fabric constitutes an integral product by knitting or knitting the fused portion together with the main fiber or covering the main fiber. This woven or knitted fabric is placed on the surface of the base material, and the peripheral edge of the woven or knitted fabric is welded to the groove wall surface by being pressed against the groove wall surface of the peripheral groove. For this reason, it is not necessary to perform operations such as sandwiching or shaping between two members as in the prior art, and it is easy to fix the woven or knitted fabric to the substrate surface.

  (2) The peripheral groove portion formed on the surface of the base material extends along the entire peripheral portion of the woven or knitted fabric, and the fusion portion provided on the entire peripheral portion of the woven or knitted fabric includes: It is preferable to weld to the groove wall surface of the said peripheral groove part. The entire peripheral edge of the woven or knitted fabric is welded to the groove wall surface of the peripheral groove, so that the entire peripheral edge of the woven or knitted fabric enters the peripheral groove and is recessed in a concave shape. For this reason, the whole peripheral part of the woven or knitted fabric is not conspicuous and looks good.

  (3) Inside the peripheral edge of the woven or knitted fabric, an opening is formed in a gap formed between the woven or knitted fabric and the base material so that the stored item can be taken in and out. Is preferred. In this case, small articles can be taken in and out of the gap from the opening, and the gap between the general part of the woven or knitted fabric and the substrate can be used as the pocket part.

  (4) A part of the peripheral portion of the woven or knitted fabric is not joined to the groove wall surface, and a stored item can be taken in and out between the base and the woven or knitted fabric. It is preferable that an opening that leads to the gap between them is formed. A part of the peripheral part of the woven or knitted fabric is welded to the groove wall surface of the peripheral groove part, so that a gap is formed between the general part not welded to the groove wall surface of the woven or knitted fabric and the base material. A part of the peripheral part of the woven or knitted fabric is opened without being fixed to the groove wall surface of the peripheral groove part. For this reason, small articles can be taken in and out of the gap from this opening, and the gap between the non-joined portion of the woven or knitted fabric and the substrate can be used as a pocket portion.

  (5) Furthermore, the inner side groove part is formed inside the said peripheral groove part of the surface of the said base material, The said melt | fusion part provided inside the peripheral part of the said woven / knitted fabric is the said inner side groove part It is preferable to weld to the groove wall surface. In this case, the woven or knitted fabric is accommodated not only in the peripheral groove portion but also in the inner groove portion, and a concave depression is formed not only in the peripheral portion of the woven or knitted fabric but also in other general portions. Therefore, several unevenness | corrugations are formed in the woven or knitted fabric, and the woven or knitted fabric can be three-dimensionally fixed to the substrate surface.

  (6) The woven or knitted fabric is preferably a mesh material having a mesh. Since the woven or knitted fabric is a mesh material, the weight of the composite member can be reduced. In addition, the surface of the substrate can be seen through through a mesh formed in the mesh material. Therefore, the design which consists of both a base material and a mesh material is formed in the surface of a composite member, and it is excellent in design property.

  (7) It is preferable that the fused portion is made of a fiber and is woven and knitted together with the main fiber to constitute the woven or knitted fabric. Since the fused portion is woven and knitted together with the main fiber to form a woven or knitted fabric, there are many entangled portions with the main fiber. For this reason, the main fiber can be firmly joined to the groove wall surface of the peripheral groove portion or the inner groove portion.

  (8) It is preferable that melting | fusing point of the said 2nd thermoplastic resin which comprises the said melt | fusion part exists in the range of +/- 50 degreeC with respect to melting | fusing point of the said 1st thermoplastic resin which comprises the said base material. Since the melting point of the fused portion of the woven or knitted fabric is close to the melting point of the base material, the fused portion of the woven or knitted fabric is surely welded to the groove wall surface of the peripheral groove portion or the inner groove portion, and the main fiber is grooved to the groove wall surface of the peripheral groove portion or the inner groove portion. Can be firmly bonded to each other.

  (9) It is preferable that the kind of said 2nd thermoplastic resin which comprises the said melt | fusion part is the same as the kind of said 1st thermoplastic resin which comprises the said base material. The melting point of the fusion part of the woven or knitted fabric can be brought close to the melting point of the base material and is compatible with each other. Therefore, the fusion part and the groove wall surface of the peripheral groove part or the inner groove part are reliably welded, and the main fiber Are firmly joined to the groove wall surfaces of the peripheral groove portion and the inner groove portion.

  (10) The method for producing a composite member of the present invention comprises a main fiber and a second thermoplastic resin having a melting point lower than that of the main fiber, and is woven or knitted together with the main fiber, or a melt that covers the main fiber. An arrangement step of arranging a woven or knitted fabric composed of a wearing portion on a surface of a base material made of a first thermoplastic resin and having a peripheral groove extending in a shape along at least a part of the peripheral portion of the woven or knitted fabric; While heating the first thermoplastic resin and the second thermoplastic resin to a temperature at which the main fibers can be melted and the main fibers are not melted and denatured, the woven or knitted fabric is groove wall surface of the peripheral groove portion of the substrate. A welding step of welding the welded portion of the peripheral edge portion of the woven or knitted fabric to the groove wall surface of the peripheral groove portion.

  According to the manufacturing method described above, the woven or knitted fabric is pressed against the groove wall surface of the peripheral groove portion while heating, so that the fused portion of the woven or knitted fabric is welded to the groove wall surface with the main fibers taken in. For this reason, the woven or knitted fabric can be firmly joined to the peripheral groove.

  Further, the woven or knitted fabric is disposed on the surface of the base material as an integral product. For this reason, it is not necessary to perform operations such as sandwiching or shaping between two members as in the prior art, and it is easy to fix the woven or knitted fabric to the substrate surface.

  Moreover, the peripheral part of the woven / knitted fabric is recessed in a concave shape by pressing the peripheral part of the woven / knitted fabric against the groove wall surface. For this reason, the general part which does not enter into the peripheral groove part of the woven or knitted fabric appears to be lifted more than the peripheral part which enters into the peripheral groove part of the woven or knitted fabric. Moreover, in the general part of the woven or knitted fabric, the uneven pattern or texture of the woven or knitted fabric itself can be visually recognized. Therefore, the woven or knitted fabric fixed on the surface of the base material has a three-dimensional effect and has a good appearance.

  (11) In the welding step, it is preferable that a heated pressing blade is caused to enter the peripheral groove portion and the peripheral portion of the woven or knitted fabric is pressed against the groove wall surface of the peripheral groove portion. The peripheral edge of the woven or knitted fabric is pushed into the peripheral groove by the heated pressing blade, and is reliably joined to the groove wall surface of the peripheral groove.

  According to the composite member and the manufacturing method thereof of the present invention, the fusion part at the peripheral edge of the woven or knitted fabric is welded to the groove wall surface of the peripheral groove formed on the surface of the base material. For this reason, the woven or knitted fabric appears to float from the surface of the base material, and can be simply fixed to the base material.

It is a perspective view of the composite member of Example 1 of this invention. FIG. 3 is a perspective view showing a usage state of the composite member of Example 1. 1 is a perspective view of a base material of Example 1. FIG. It is explanatory drawing (a) of the network structure of a woven / knitted fabric of Example 1, and the organization organization chart (b) of a woven / knitted fabric. It is AA arrow sectional drawing of FIG. It is BB arrow sectional drawing of Example 1 for demonstrating the method of thermally welding the peripheral part of the woven / knitted fabric to the bottom part and inner side part of a groove wall surface in Example 1. FIG. It is principal part sectional drawing of the composite member for showing the method of thermally welding the peripheral part of the woven / knitted fabric in the inner side part of a groove wall surface in Example 1. FIG. It is principal part sectional drawing of the composite member for showing the method of heat-welding the peripheral part of the woven / knitted fabric to the bottom part, inner side part, and outer side part of a groove wall surface in Example 1. FIG. 6 is a perspective view of a composite member of Example 2. FIG. 10 is a perspective view of a composite member of Example 3. FIG. It is the perspective view seen from the back side of the seat of the vehicle in a prior art example. It is the exploded perspective view (a) of the seat back member seen from the surface side in a prior art example, and the exploded perspective view (b) of the seat back member seen from the back side. It is a top view of a pocket in other conventional examples. It is explanatory drawing which shows the 1st manufacturing method of the conventional interior member. It is explanatory drawing which shows the 2nd manufacturing method of the conventional interior member. It is explanatory drawing which shows the 3rd manufacturing method of the conventional interior member.

  A composite member and a manufacturing method thereof according to an embodiment of the present invention will be described.

  The composite member is formed by fixing the peripheral edge of the woven or knitted fabric to the surface of the base material.

  The base material is comprised from the 1st thermoplastic resin. As the first thermoplastic resin, for example, polypropylene (PP), polyethylene (PE), or the like can be used. The base material may contain fillers such as talc and fibers in addition to the first thermoplastic resin.

  On the surface of the base material, a peripheral groove portion is formed at a portion where the peripheral portion of the woven or knitted fabric is disposed. The peripheral groove part is formed in the part in which at least one part of the peripheral part of a woven / knitted fabric is arrange | positioned in the base-material surface. For example, the peripheral groove part is formed in the part in which the part of the peripheral part of a knitted fabric is arrange | positioned in the base-material surface along the extension direction of a part of peripheral part. In this case, a part of the fusion part of the peripheral part of the woven or knitted fabric is welded to the groove wall surface surrounding the peripheral groove part of the base material. Moreover, the peripheral groove part may be formed in the part in which the whole peripheral part of a woven / knitted fabric is arrange | positioned in the base-material surface. In this case, the entire peripheral edge of the woven or knitted fabric is welded to the groove wall surface surrounding the peripheral groove of the base material.

  The groove depth H1 of the peripheral groove is preferably 1 to 5 mm, and more preferably 2 to 3 mm. In this case, the peripheral part of the woven or knitted fabric enters the peripheral groove part, and the general part other than the peripheral part is lifted and looks three-dimensional. Further, the welded portion of the woven or knitted fabric is welded to the entire groove wall surface, so that the woven or knitted fabric can be firmly joined.

  The groove width L1 of the peripheral groove is preferably 2 to 10 mm, and more preferably 3 to 5 mm. In this case, the welded portion of the woven or knitted fabric is welded to the entire groove wall surface, and the woven or knitted fabric can be firmly joined.

  On the surface of the substrate, an inner groove portion may be formed inside the peripheral groove portion. A part of the woven or knitted fabric enters the inner groove, and a part of the woven or knitted fabric is welded to the groove wall surface. The groove depth H2 of the inner groove portion is preferably 1 to 5 mm, and more preferably 2 to 3 mm, similarly to the groove depth H1 of the peripheral groove portion. Further, the groove width L2 of the inner groove portion is preferably 2 to 10 mm, and preferably 3 to 5 mm, similarly to the groove width L1 of the peripheral groove portion.

  The woven or knitted fabric is a woven fabric or a knitted fabric. When the woven or knitted fabric is a woven fabric, it may be woven by any one of a plain weave, a twill weave, a satin weave, or a combination thereof. When the knitted fabric is a knitted fabric, it may be knitted by tricot knitting, lace knitting, mesh knitting, Afghan knitting, bar needle knitting, crochet knitting, or the like.

  The woven or knitted fabric is preferably a mesh material having a mesh. At the time of welding, the heat applied from the heating device is easily transferred between the front and back of the mesh material through the mesh space, and the heat is sufficiently transferred to the groove wall surface to which the mesh material is pressed, so that the fused portion is welded to the groove wall surface. Thus, the mesh material can be reliably fixed to the groove wall surface. Further, the heating temperature can be lowered and the heating time can be shortened.

  The mesh material mesh is a substantially rectangular through-hole, and the mesh size (long width if there is a long width and short width) is at least three times the diameter of the braid that surrounds the mesh. It is preferable. In this case, heat is easily transmitted between the front and back surfaces of the mesh material and the groove wall surface through the mesh, and the fused portion of the mesh material can be surely welded to the groove wall surface.

  The main structure of the mesh structure of the mesh material is preferably knitted with main fibers. When the fused portion is welded to the groove wall surface, the main fiber does not melt, so that the mesh structure of the mesh material can be maintained.

  An opening may be formed inside the peripheral edge of the woven or knitted fabric. The opening is preferably opened in a gap formed between the knitted and knitted fabric and the base material to a size that allows the stored item to be taken in and out. In this case, a woven or knitted fabric can be used as the pocket portion.

  Moreover, when forming a pocket part in a composite member, you may form the opening part which leads to a clearance gap by leaving the part which is not welded to a base material in a part of peripheral part of a woven / knitted fabric.

  The woven or knitted fabric is composed of a main fiber and a fused portion. The main fibers form a woven or knitted structure. The fused part may constitute a fibrous fused fiber. The fused fiber may be bundled together with the main fiber to constitute a composite yarn, or may be bundled only with the fused fiber independently of the main fiber to constitute a single yarn. These yarns may be spun yarns obtained by twisting short fibers or filament yarns obtained by twisting long fibers.

  In the case where the fused fiber constitutes a yarn separately from the main fiber, a mesh is formed with the yarn made of the main fiber, and the yarn made of the fused fiber may be knitted while being entangled with the yarn made of the main fiber.

  Moreover, the fusion | fusion part may coat | cover the surface of the main fiber. When the fusion part covers the surface of the main fiber, the fusion part and the main fiber form a core cover composite fiber in which the main fiber constitutes the core part and the fusion part constitutes the cover part. is doing.

  The fused part may be woven or knitted together with the main fiber in all parts of the woven or knitted fabric, or may cover the surface of the main fiber. Further, the fused portion may be woven or knitted together with the main fiber in a part of the woven or knitted fabric, or may cover the surface of the main fiber. The fused part is woven or knitted with the main fiber only at the part of the woven or knitted fabric that joins at least the surface of the base material, that is, only the entry part that enters the peripheral groove part or the inner groove part of the woven or knitted article. It is only necessary to cover the surface of the main fiber.

  The main fiber of the woven or knitted fabric may be made of any material. Main fibers include, for example, polyarylate fibers, polyester fibers such as polyethylene terephthalate (PET) fibers, polyamide fibers, acrylic fibers, synthetic fibers such as polyarylate fibers, mineral fibers such as glass fibers and carbon fibers, cotton, hemp, silk Natural fibers such as hair are preferable.

  The main fiber may be a reinforcing fiber. In this case, the strength of the woven or knitted fabric is improved, and the woven or knitted fabric is hardly broken. Examples of the reinforcing fiber include polyarylate fiber, polyester fiber such as PET, glass fiber, polyamide fiber, and carbon fiber.

  The bending elastic modulus (JISK-7171) of the material used as the reinforcing fiber is preferably 3000 MPa or more, and more preferably 5000 MPa or more. In this case, the rigidity of the woven or knitted fabric can be increased.

  The main fiber may be a short fiber or a long fiber. In addition, the main fibers may be formed by bundling a plurality of single materials, or may be formed by bundling a plurality of types of materials.

  The fused part is made of a second thermoplastic resin having a melting point lower than the melting point of the main fiber material. The melting point of the second thermoplastic resin may be close to the melting point of the first thermoplastic resin constituting the substrate. The difference between the melting point of the second thermoplastic resin and the melting point of the first thermoplastic resin is preferably within ± 50 ° C., more preferably within ± 30 ° C., and preferably within ± 10 ° C. In this case, since the fused part melts together with the groove wall surface of the peripheral groove part during heating, it can be reliably welded to the groove wall surface.

  For example, PP and PE can be used as the second thermoplastic resin constituting the fusion part. The fused portion may be a mixture of the second thermoplastic resin with a filler or talc.

  The melting point of the second thermoplastic resin that constitutes the fused portion and the melting point of the first thermoplastic resin that constitutes the base material are relatively close to each other. It should be considerably higher than the melting point of the second thermoplastic resin. For example, the melting point of the material that can be the main fiber is preferably 55 ° C. or more higher than the melting points of the first and second thermoplastic resins.

  The second thermoplastic resin is preferably the same type as the first thermoplastic resin constituting the substrate. Not only is the melting point of the second thermoplastic resin easy to approximate the melting point of the first thermoplastic resin, but also the compatibility with each other is good, so the fused part is a groove in the peripheral groove part or the inner groove part formed in the base material. The main fiber can be securely bonded to the wall surface and firmly bonded to the groove wall surface. Here, the term “type” means that not only the components of the polymer constituting the thermoplastic resin are the same, but also the main monomers of the polymer constituting the thermoplastic resin are the same. The case where the molecular weights of the first and second thermoplastic resins are slightly different or the structures are slightly different are also included in the “same type”.

  The first thermoplastic resin and the second thermoplastic resin may both be PP or PE, for example.

  Table 1 shows an example of the main fiber, the fused portion, and the base material, and their softening point, melting point, and thermal conductivity.

織編物の中の少なくとも溝壁面に溶着される部分では、主繊維１００質量部に対する融着部の質量比率が、例えば、５〜６０質量部であるとよい。５質量部未満では、融着部が主繊維に対して相対的に少なすぎ、主繊維の溝壁面への接合性が低下するおそれがある。６０質量部を超える場合には、溝壁面へ接合する主繊維の相対量が少なく、織編物の溝壁面への接合部分の強度が低下するおそれがある。

In the portion of the woven or knitted fabric that is welded to at least the groove wall surface, the mass ratio of the fusion part to 100 parts by mass of the main fiber may be, for example, 5 to 60 parts by mass. If it is less than 5 mass parts, there are too few fusion parts with respect to a main fiber, and there exists a possibility that the bondability to the groove wall surface of a main fiber may fall. When the amount exceeds 60 parts by mass, the relative amount of main fibers bonded to the groove wall surface is small, and the strength of the bonded portion of the woven or knitted fabric to the groove wall surface may be reduced.

  In manufacturing the composite member, the following arrangement process and welding process are performed.

  In the arranging step, the woven or knitted fabric is arranged on the surface of the substrate. A peripheral groove portion extending in a shape along at least a part of the peripheral portion of the woven or knitted fabric is formed on the surface of the base material. When the woven or knitted fabric is arranged on the surface of the substrate, the woven or knitted fabric is arranged so that the peripheral edge of the woven or knitted fabric is positioned on the peripheral groove. The peripheral part of the woven or knitted fabric may cover only the inner part of the groove wall surface surrounding the peripheral groove part (FIG. 7), or may cover the inner part and the bottom part (FIG. 6), or the inner part and the bottom part. The outer portion may be covered (FIG. 8).

  In the welding step, the peripheral edge of the woven or knitted fabric is pressed against the groove wall surface of the peripheral groove while heating. At this time, the heating temperature of the woven or knitted fabric is such that the first thermoplastic resin constituting the base material and the second thermoplastic resin constituting the fusion part can be melted, and the main fiber does not melt and deform. Temperature is good. The heating temperature is preferably higher than the melting points of the first and second thermoplastic resins and lower than the softening point of the material constituting the main fiber.

  For example, the first thermoplastic resin constituting the base material is PP (melting point 150 to 170 ° C.), the second thermoplastic resin constituting the fusion part is PP (melting point 173 ° C.), and the main fiber Is formed from polyester (softening point 240 ° C., melting point 250 ° C.), the heating temperature should be greater than 173 ° C., less than 240 ° C., and 180-230 ° C. Is good.

  The heating time of the woven or knitted fabric is preferably 20 to 180 seconds, and more preferably 30 to 90 seconds. In this case, the fused portion of the woven or knitted fabric and the groove wall surface of the base material are welded to each other, so that the woven or knitted fabric can be firmly bonded to the groove wall surface.

  Only the portion of the woven or knitted fabric facing the groove wall surface is preferably heated intensively. By melting only the portion welded to the groove wall surface of the woven or knitted fabric, it is possible to prevent the general portion other than the portion facing the groove wall surface of the woven or knitted fabric from welding to the substrate surface.

  To heat only the portion of the woven or knitted fabric facing the groove wall surface, the heated pressing blade is allowed to enter the peripheral groove portion covered with the woven or knitted fabric, and the woven or knitted fabric is pressed against the groove wall surface with the pressing blade. Good.

  The composite member of the present invention is used for, for example, a vehicle interior part. Examples of such vehicle interior parts include, but are not limited to, a seat backboard, a console lid, an instrument panel, a door trim, a tonneau cover, a trunk room floor member, and a cargo room panel member. Moreover, the composite member of this invention can be used also as furniture, a building member, a net shelf etc. besides a vehicle interior component. In particular, when a woven or knitted fabric is used as the pocket portion, for example, the composite member can be used as a seat backboard or the like.

Example 1
As shown in FIGS. 1 and 2, the composite member of this example fixes the peripheral portion 20 of the woven or knitted fabric 2 to the surface of the base material 1 to form a pocket portion 4 in which the accommodation 7 can be taken in and out. .

The base material 1 is a seat back board of the front seat of the vehicle. The material of the substrate 1 is PP containing filler, and is composed of 50 to 70 parts by mass of PP and 20 parts by mass of filler (talc). The softening point of the PP with filler is 150 ° C., the melting point is 165 ° C., and the thermal conductivity is 3.3 × 10 ⁴ cal / cm · sec · ° C. (Table 1).

  As shown in FIG. 3, a peripheral groove portion 10 extending in a frame shape along the peripheral portion 20 of the woven or knitted fabric 2 is formed on the surface of the base material 1. Further, an inner groove portion 12 extending in the lateral direction is formed inside the peripheral groove portion 10 on the surface of the substrate 1. The groove depth H1 of the peripheral groove portion 10 and the inner groove portion 12 is 3 mm, and the groove width L1 is 5 mm (FIG. 6).

  As shown in FIG. 4, the woven or knitted fabric 2 is a mesh material having a mesh 28 and is knitted by a multi-axis knitting machine. The woven or knitted fabric 2 can be expanded and contracted by expanding or contracting the mesh 28.

  The woven or knitted fabric 2 is knitted with the main fiber yarn 21 and the fused fiber yarn 22. The mesh material has a mesh structure formed by warp knitting (warp knitting). In order to prevent excessive deformation of the mesh 28 of the mesh structure, the weft knitting yarn (weft knitting yarn) 23 is entangled with the warp knitting yarn (warp knitting yarn) 24 so as to cross the mesh 28. The weft yarn 23 is composed only of the main fiber yarn 21. The warp knitting yarn 24 is composed of one main fiber yarn 21 and one fusion fiber yarn 22. The fused fiber yarn 22 is knitted as a warp yarn 24 together with the main fiber yarn 21 on the entire woven or knitted fabric 2. The short width A of the mesh 28 is 13 mm, and the long width B is 20 mm. The width C of the knitting leg 25 surrounding the mesh 28 is 2 mm.

Each of the main fiber yarn 21 and the fused fiber yarn 22 is a filament yarn obtained by twisting a plurality of long fibers. The main fiber yarn 21 is made of polyarylate fiber (700 tex), which is a kind of reinforcing fiber, and the fused fiber yarn 22 is made of polypropylene fiber (300 tex). The polyarylate constituting the main fiber yarn 21 has a softening point of 300 ° C., a melting point of 400 ° C., and a thermal conductivity of 3.5 × 10 ⁴ cal / cm · sec · ° C. The softening point of PP constituting the fused fiber yarn 22 is 145 ° C., the melting point is 173 ° C., and the thermal conductivity is 3.3 × 10 ⁴ cal / cm · sec · ° C. (Table 1).

  The fusion fiber yarn 22 has a mass ratio of 40 mass parts when the main fiber of the main fiber yarn 21 is 100 mass parts.

  As shown in FIG. 5, the peripheral edge 20 of the woven or knitted fabric 2 is joined to the groove wall surface 11 surrounding the peripheral groove 10 formed on the surface of the substrate 1. The fused fiber yarn 22 of the woven or knitted fabric 2 is welded to the groove wall surface 11 and the peripheral portion 20 of the woven or knitted fabric 2 is joined in a state where the main fiber yarn 21 is taken in.

  As shown in FIG. 1, an opening 25 is formed inside the peripheral edge 20 of the woven or knitted fabric 2. The opening 25 extends in the left-right direction, and is open to the extent that small articles can be taken in and out of the gap between the knitted fabric 2 and the substrate 1. The upper part of the peripheral edge of the opening 25 is welded to the groove wall surface of the inner groove 12 formed on the surface of the substrate 1. The lower part of the peripheral edge of the opening 25 is edged with a bias tape 25a to prevent fraying.

  In manufacturing the composite member, a base material 1 and a woven or knitted fabric 2 are prepared. As shown in FIG. 3, the peripheral groove portion 10 and the inner groove portion 12 are formed on the surface of the substrate 1. The woven or knitted fabric 2 is disposed on the surface of the substrate 1 and the peripheral edge 20 of the woven or knitted fabric 2 is positioned in the peripheral groove 10.

  On the other hand, as shown in FIG. 6, a welding apparatus having a pressing blade 30 protruding along the shape of the peripheral groove portion 10 and the inner groove portion 12 is prepared. A heating wire (not shown) is embedded in the pressing blade 30 so that the temperature can be adjusted. The pressing blade 30 is positioned on the base material 1 on which the woven or knitted fabric 2 is disposed, and gradually approaches the base material 1. Eventually, the pressing blade 30 is pushed into the peripheral groove portion 10 and the inner groove portion 12, and the woven or knitted fabric 2 is pressed against the groove wall surfaces 11 of the peripheral groove portion 10 and the inner groove portion 12. The pressing blade 30 is set to 200 ° C. and pressed against the groove wall surface 11 with a load of 0.2 MPa for 60 seconds. As a result, the fused fiber yarn 22 of the woven or knitted fabric 2 is melted or softened, and the groove wall surface 11 of the peripheral groove portion 10 and the inner groove portion 12 is also melted or softened, so that the fused fiber yarn 22 is welded to the groove wall surface 11. .

  Here, as shown in FIG. 6, the peripheral edge 20 of the woven or knitted fabric 2 faces the inner side and the bottom of the groove wall surface 11 of the peripheral groove 10. However, the peripheral edge 20 of the woven or knitted fabric 2 may face only the inner part of the groove wall surface 11 of the peripheral groove part 10 (FIG. 7), or may face the inner part, the bottom part, and the outer part (FIG. 7). 8). In either case, the peripheral edge 20 of the woven or knitted fabric 2 is reliably bonded to the groove wall surface 11 of the peripheral groove 10.

  Moreover, since a composite member is produced by welding the woven or knitted fabric 2 to the peripheral groove portion 10 of the substrate 1, the number of parts can be reduced and the number of steps can be reduced.

  Moreover, the general part 27 which is a part other than the peripheral part of the woven or knitted fabric 2 has a non-joined part that is not joined to the base material 1. Since the general part 27 of the woven / knitted fabric 2 appears on the base material 1 like the woven / knitted fabric only placed on the base material 1, The formed concavo-convex pattern and texture can be visually recognized as they are.

  In addition, the general portion 27 that has not entered the peripheral groove portion 10 of the woven or knitted fabric 2 appears to be lifted with respect to the peripheral portion 20 that has entered the peripheral groove portion 10 of the woven or knitted fabric 2.

  Thus, the woven or knitted fabric 2 looks three-dimensional as if it was lifted on the surface of the substrate 1 while maintaining its own uneven pattern and texture. For this reason, the composite member of this example has good appearance and excellent design.

  Even when the peripheral edge portion 20 of the woven or knitted fabric 2 is frayed, the peripheral edge portion 20 of the woven or knitted fabric 2 is not conspicuous because the peripheral groove portion 10 formed in the substrate 1 is recessed. Moreover, at the peripheral edge 20 of the woven or knitted fabric 2, the fused fiber yarn 22 is welded to the groove wall surface 11 while being intertwined with the main fiber yarn 21. For this reason, fraying of the main fiber yarn 21 can be prevented. Even if there is a frayed portion in the peripheral edge portion 10 of the woven or knitted fabric 2, the frayed portion of the peripheral edge portion 20 of the woven or knitted fabric 2 is not conspicuous because the peripheral groove portion 10 is recessed.

  In addition, the knitted and knitted fabric 2 constitutes an integrated product by knitting and knitting the fused fiber yarn 22 together with the main fiber yarn 21. The woven or knitted fabric 2 is disposed on the surface of the base material 1 and welded to the groove wall surface 11 by being pressed against the groove wall surfaces 11 of the peripheral groove portion 10 and the inner groove portion 12 formed on the surface of the base material 1. For this reason, it is not necessary to perform operations such as sandwiching or shaping between two members as in the prior art, and it is easy to fix the woven or knitted fabric to the substrate surface.

(Example 2)
In the composite member of this example, as shown in FIG. 9, the left and right side portions and the lower portion of the peripheral portion 20 of the woven or knitted fabric 2 are joined to the groove wall surface 11 of the peripheral groove portion 10 of the substrate 2, but the upper portion is open. Thus, an opening 26 is formed. The size of the opening 26 is a size that allows the storage of small items, magazines, books, and the like. The knitted or knitted fabric 2 constitutes a pocket portion that can accommodate a stored item in a gap between the base material 1 and the knitted fabric 2. A rubber band is passed through the upper part of the peripheral edge 20 of the knitted and knitted fabric 2, and the opening 26 is held near the surface of the base material 1 to prevent dropping of the accommodated material accommodated in the gap from the opening 26. ing. Other configurations are the same as those of the first embodiment.

(Example 3)
In the composite member of this example, as shown in FIG. 10, the woven or knitted fabric 2 has no opening, and the entire peripheral edge 20 of the woven or knitted fabric 2 is formed on the groove wall surface of the peripheral groove 10 formed on the surface of the substrate 1. It is joined. The base material 1 is a door trim. In this example, the woven or knitted fabric 2 is a mesh material similar to the woven or knitted fabric used in Example 1, and is used as a decorating material for decorating the door trim.

  Not only the peripheral edge portion 20 of the woven or knitted fabric 2 but also a part of the general portion 27 is joined to the groove wall surface of the inner groove portion 12 formed in the substrate 1. The inner groove portion 12 is formed on the surface of the substrate 1 so as to cross the center of the region surrounded by the peripheral groove portion 10. A fused fiber yarn constituting the central portion of the general portion 27 of the woven or knitted fabric 2 is welded to the groove wall surface of the inner groove portion 12. The groove depth H2 of the inner groove portion 12 is 3 mm, and the groove width L2 is 5 mm. Other configurations are the same as those of the third embodiment.

  The general portion 27 of the woven or knitted fabric 2 has a portion that is not joined to the base material 2. In the general portion 27 of the knitted or knitted fabric 2, since the entire woven or knitted fabric 2 appears on the base material 1, the concavo-convex pattern or texture formed on the woven or knitted fabric 2 itself can be visually recognized.

  Moreover, the peripheral part 20 of the woven or knitted fabric 2 enters the peripheral groove part 10 and is recessed in a concave shape. On the other hand, the general portion 27 that does not enter the peripheral groove portion 20 of the woven or knitted fabric 2 appears to be lifted with respect to the peripheral portion 20 that has entered the peripheral groove portion 10 of the woven or knitted fabric 2. For this reason, the general part 27 of the woven or knitted fabric 2 floats on the surface of the substrate 1 and looks three-dimensional. Therefore, the portion of the door trim where the woven or knitted fabric 2 is disposed can be three-dimensionally decorated, and the design of the door trim is enhanced.

  Thus, the woven or knitted fabric 2 looks three-dimensional as if it was raised on the surface of the base material while maintaining its own uneven pattern and texture, and is excellent in design.

  Moreover, the arrangement | positioning of the unevenness | corrugation of the woven / knitted fabric 2 formed by joining to the peripheral groove part 10 can be changed freely by changing various arrangement | positioning of the peripheral groove part 10 formed in the base material 1 surface. Therefore, the degree of freedom in designing the unevenness formed on the woven or knitted fabric 2 is high, and the design is excellent.

<Experimental example>
In this experimental example, a test piece of a composite member was produced and the peeling strength was measured.

  The test piece of the composite member has the same configuration as that of the first embodiment. The test piece is obtained by joining a woven or knitted fabric to the surface of a base material. The base material was a strip shape with a thickness of 10 mm. The woven or knitted fabric was in the form of a strip with a width of 50 mm, and was placed in the center of the substrate. Similar to Example 1, the woven or knitted fabric is made of a mesh material and is knitted with main fiber yarns and fusion fiber yarns. A peripheral groove portion extending along the peripheral edge of the woven or knitted fabric is formed on the surface of the base material, the woven or knitted fabric is disposed in the peripheral groove, and the fused fiber yarn of the peripheral portion of the woven or knitted fabric is welded to the groove wall surface. ing.

  The peripheral part of the woven or knitted fabric at one end of the test piece was peeled off and attached to one end of the woven or knitted fabric from which the grip of the tensile tester was peeled off, the tensile load curve was measured, the maximum tensile load was obtained, and the peeling strength was obtained.

  As a result, the peeling strength of the test piece was 59.6 N / 50 mm. This degree of peeling strength is much higher than the load assumed to be applied to the woven or knitted fabric when the woven or knitted fabric is used as a pocket portion. This shows that the peripheral part of the woven or knitted fabric is firmly joined to the peripheral groove part of the base material.

1: base material, 2: woven or knitted fabric, 3: welding device, 4: pocket portion, 10: peripheral groove portion, 11: groove wall surface, 12: inner groove portion, 20: peripheral portion, 21: main fiber yarn, 22: fusion Fiber yarn, 23: warp knitting yarn, 24: weft knitting yarn, 25, 26: opening, 27: general portion, 28: mesh, 30: pressing blade.

Claims (11)

A composite member comprising a base material made of a first thermoplastic resin and a woven or knitted fabric covering the surface of the base material and partially fixed to the surface of the base material,
The woven or knitted fabric includes a main fiber and a fusion part made of a second thermoplastic resin having a melting point lower than that of the main fiber. Is the fusion part woven or knitted together with the main fiber? Or covering the main fiber,
A peripheral groove portion extending along at least a part of a peripheral portion of the woven or knitted fabric is formed on the surface of the base material, and at least a part of the fusion portion of the peripheral portion of the woven or knitted fabric is the peripheral groove portion. A composite member characterized by being welded to the wall surface of the groove.   The peripheral groove portion formed on the surface of the base material extends along the entire peripheral portion of the woven or knitted fabric, and the fusion portion provided on the entire peripheral portion of the woven or knitted fabric includes the peripheral groove portion. The composite member according to claim 1, which is welded to the groove wall surface.   The opening part which can take in / out a thing is formed in the clearance gap formed between the said woven / knitted fabric and the said base material inside the peripheral part of the said woven / knitted fabric. Composite member.   A part of the peripheral edge of the woven or knitted fabric is not joined to the groove wall surface, and the space between the woven and knitted fabric and the base material can be taken into and out of the base material. The composite member according to claim 1, wherein an opening that leads to is formed.   Further, an inner groove is formed inside the peripheral groove on the surface of the base material, and the fusion part provided inside the peripheral edge of the woven or knitted fabric is a groove wall surface of the inner groove. The composite member according to any one of claims 1 to 4, wherein the composite member is welded.   The composite member according to any one of claims 1 to 5, wherein the woven or knitted fabric is a mesh material having a mesh.   The composite member according to any one of claims 1 to 6, wherein the fusion part is made of a fiber, and is woven and knitted together with the main fiber to form the woven or knitted fabric.   The melting point of the second thermoplastic resin constituting the fusion part is in a range of ± 50 ° C with respect to the melting point of the first thermoplastic resin constituting the base material. The composite member according to claim 1.   The composite member according to any one of claims 1 to 8, wherein a kind of the second thermoplastic resin constituting the fusion part is the same as that of the first thermoplastic resin constituting the base material. . A woven or knitted fabric comprising a main fiber and a second thermoplastic resin having a melting point lower than that of the main fiber, which is woven or knitted together with the main fiber, or composed of a fused portion covering the main fiber. A disposing step of disposing a peripheral groove extending in a shape along at least a part of the peripheral portion of the substrate and disposing the peripheral groove on the surface of the base material made of the first thermoplastic resin;
While heating the first thermoplastic resin and the second thermoplastic resin to a temperature at which the main fibers can be melted and the main fibers are not melted and denatured, the woven or knitted fabric is groove wall surface of the peripheral groove portion of the substrate. And a welding step of welding the welded portion of the peripheral portion of the woven or knitted fabric to the groove wall surface of the peripheral groove portion.   The manufacturing method of the composite member according to claim 10, wherein in the welding step, a heated pressing blade is caused to enter the peripheral groove portion and the peripheral portion of the woven or knitted fabric is pressed against a groove wall surface of the peripheral groove portion.

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