JP2015086480A - Fiber board - Google Patents

Abstract

PROBLEM TO BE SOLVED: To reduce cost of a fiber board.SOLUTION: A trim board 11 comprises a fiber, a thermoplastic resin, and a heat-expandable capsule 34, and has an upper part Y1 of the trim board 11 and a lower part Y2 of the trim board 11 which is a portion where the blend rate of the heat-expandable capsule 34 is lower than that in the upper part Y1. The lower part Y2 of the trim board 11 has a main surface part 22A that constitutes a main surface of the trim board 11 and a standing wall part 22B rising up from a periphery of the main surface part 22A to the back.

Description

  The present invention relates to a fiber board.

  Conventionally, the thing of the following patent document 1 is known as a fiber board containing a fiber and a thermoplastic resin. In the fiber board of Patent Document 1, thermally expandable capsules are dispersed in the fiber. The thermally expandable capsule is expanded by being heated at the time of manufacture. Thereby, weight reduction of a fiber board can be achieved.

JP 2009-179896 A

  In the above-mentioned fiber board, generally, the greater the amount of thermally expandable capsules, the higher the rigidity. This is thought to be because the thermoplastic resin constituting the thermally expandable capsule melts to bind the fibers together.

  Further, the heat-expandable capsule is generally blended at a uniform ratio throughout the fiber board. On the other hand, the rigidity of the fiber board is not uniform throughout the board and may vary from part to part. For example, in a fiber board where the shape is complicated, the rigidity is relatively high. For this reason, when a thermally expansible capsule is mix | blended in a uniform ratio over the whole fiber board, rigidity may become excessively higher than the value as which depending on a part. Since such excessive quality leads to an increase in cost, there is room for improvement.

  This invention is completed based on the above situations, Comprising: It aims at reducing the cost of a fiber board.

  In order to solve the above-mentioned problems, the present invention provides a fiber board including fibers, a thermoplastic resin, and a thermally expandable capsule, wherein the first predetermined portion and the heat of the first predetermined portion are compared with the first predetermined portion. And a second predetermined part which is a part where the amount of the expandable capsule is small.

  According to the present invention, the thermally expandable capsule is reduced in the first predetermined portion and the first predetermined portion by making the blending amount of the thermally expandable capsule in the second predetermined portion smaller than the blending amount of the thermally expandable capsule in the first predetermined portion. 2 The amount of thermally expandable capsules used can be reduced and the cost for manufacturing can be reduced as compared with a configuration in which the predetermined parts are blended at a uniform ratio.

  Said structure WHEREIN: The said 2nd predetermined part is provided with the main surface part which comprises the main surface of the said fiber board, and the standing wall part which stands | starts up in the plate | board thickness direction of the said main surface part from the peripheral edge part of the said main surface part. Can be.

  Since the 2nd predetermined part is provided with a standing wall part, rigidity is high compared with the composition provided only with the principal surface part. For this reason, even if it is a case where the compounding quantity of the thermally expansible capsule of a 2nd predetermined part is decreased, rigidity can be ensured.

  Moreover, a to-be-attached part shall be attached to the said 2nd predetermined part.

  By attaching the part to be attached, the rigidity of the second predetermined portion becomes higher. For this reason, even if it is a case where the compounding quantity of the thermally expansible capsule of a 2nd predetermined part is decreased, rigidity can be ensured.

  Moreover, the said fiber board can be used as a vehicle interior material.

  Further, the fiber board is a trim board constituting a vehicle door trim, the first predetermined portion is an upper portion of the trim board, and the second predetermined portion is a lower portion of the trim board. It can be configured.

  The lower part of the trim board generally has a complicated shape, and a mounted part is often attached. For this reason, the lower part of the trim board tends to be more rigid than the upper part. For this reason, even if it is a case where the compounding quantity of the thermally expansible capsule of the 2nd predetermined part which is the lower part of a trim board is decreased, it is easy to ensure rigidity.

  According to the present invention, the cost of the fiber board can be reduced.

The perspective view which shows the trim board which concerns on one Embodiment of this invention. 1 is a cross-sectional view showing the trim board of FIG. 1 (corresponding to a view taken along line II-II of FIG. 1). Sectional view showing the supply process Sectional drawing which shows a supply process (it corresponds to the figure cut | disconnected by the IV-IV line of FIG. 3) Cross-sectional view showing the dispersion process Sectional view showing the melting process Sectional view showing the expansion process Sectional view showing the molding process The graph which shows the effect of this embodiment

  An embodiment of the present invention will be described with reference to FIGS. In this embodiment, the trim board 11 which comprises the vehicle door trim 10 (vehicle interior material) is illustrated as a fiber board.

  FIG. 1 is a perspective view of a vehicle door trim 10. The vehicle door trim 10 includes a trim board 11 having a plate shape. Further, the vehicle door trim 10 includes an armrest 14, a speaker grill 15, an ornament 16, and the like.

  In the vehicle door trim 10, a door pocket 20 is provided below the armrest 14. As shown in FIG. 2, the door pocket 20 includes a bulging portion 21 formed by bulging a part of the trim board 11 toward the vehicle interior side (lower side in FIG. 2), and an opening of the bulging portion 21. A door pocket base material 23 that is closed from the outside.

  As shown in FIG. 2, the bulging portion 21 includes a main surface portion 22A constituting the main surface of the trim board 11, and a back end (in the thickness direction) of the main surface portion 22A from the side end portion (circumferential end portion) of the main surface portion 22A. On the other hand, a pair of standing wall portions 22B and 22B rising up is provided.

  As shown in FIG. 2, a silencer pad 26 (attached part) that functions as a soundproofing material (sound insulating material or sound absorbing material) is attached to the outside of the passenger compartment in the door pocket 20. The silencer pad 26 is made of, for example, a plate-like felt material molded into a predetermined shape.

  The trim board 11 includes reinforcing fibers, a thermoplastic resin, and a thermally expandable capsule. The fiber is, for example, vegetable fiber such as kenaf, hemp, flux, and sisal. The fibers are not limited to vegetable fibers, and may be inorganic fibers such as glass fibers and carbon fibers.

  Examples of the thermoplastic resin included in the trim board 11 include polyolefin, polyester resin, polystyrene resin, acrylic resin, polyamide resin, polycarbonate resin, polyacetal resin, and ABS resin.

  The thermally expandable capsule has a shell wall made of a thermoplastic resin and a foaming agent (expanding component) accommodated in the shell wall. When the thermally expandable capsule is heated, the foaming agent begins to expand at a predetermined temperature, and the shell wall is softened, whereby the volume of the entire thermally expandable capsule increases.

  In addition, as a shell wall which comprises a thermally expansible capsule, the same material as the thermoplastic resin which comprises the trim board 11 may be sufficient, and the thermoplastic resin of a different material may be sufficient. Specifically, as the shell wall constituting the thermally expandable capsule, acrylonitrile resin, acrylic ester, methacrylic ester, aromatic vinyl compound, aliphatic vinyl compound, vinyl chloride, vinylidene chloride and crosslinkable monomer Etc. can be illustrated.

  Moreover, hydrocarbons can be illustrated as a foaming agent contained in a thermally expansible capsule. Specifically, aliphatic hydrocarbons such as propane, n-butane, isobutane, n-pentane, isopentane, n-hexane, isohexane and n-octane, alicyclic hydrocarbons such as cyclopentane, cyclohexane and methylcyclohexane, Examples thereof include chlorinated hydrocarbons such as methyl chloride and ethyl chloride, and halogenated hydrocarbons such as fluorinated hydrocarbons such as 1,1,1,2-tetrafluoroethane and 1,1-difluoroethane.

  As such a heat-expandable capsule, for example, Matsumoto Microsphere manufactured by Matsumoto Yushi Seiyaku Co., Ltd. can be used, but it is not limited thereto.

  In the trim board 11 of this embodiment, the compounding quantity of a thermally expansible capsule changes with parts. Specifically, the blending amount of the thermally expandable capsule in the lower portion Y2 (second predetermined portion, see FIG. 1) of the trim board 11 including the bulging portion 21 is in the upper portion Y1 (first predetermined portion) of the trim board 11. It is set to be less than the blending amount of the thermally expandable capsule.

  In the present embodiment, a portion above the center portion of the trim board 11 in the vertical direction is an upper portion Y1, and a portion below the center portion is a lower portion Y2. In the present embodiment, the lower portion Y2 of the trim board 11 is, for example, a portion below the armrest 14 in the trim board 11, but is not limited thereto.

  In addition, the compounding quantity of the thermally expansible capsule in this embodiment is the compounding quantity (mass part) of the thermally expansible capsule with respect to a total of 100 mass parts of the fiber which comprises the trim board 11, and a thermoplastic resin.

  For example, 6 parts by mass of thermally expandable capsules are blended in the upper part Y1 of the trim board 11, and 4 parts by mass of thermally expandable capsules are blended in the lower part Y2 of the trim board 11, for example. In addition, the compounding quantity of the thermally expansible capsule in the trim board 11 can be changed suitably.

  Next, a method for manufacturing the trim board 11 will be described. The manufacturing method of the trim board 11 in the present embodiment includes a mat manufacturing process for manufacturing a mat 30 including fibers and a thermoplastic resin, a capsule supplying process for supplying a thermally expandable capsule 34 to the mat 30, and a mat 30 inside. The dispersion step of dispersing the thermally expandable capsule 34, the melting step of melting the thermoplastic resin inside the mat 30, the expansion step of expanding the thermally expandable capsule 34, and the trim board 11 by press-molding the mat 30 And a molding process.

(Matte manufacturing process)
In the mat manufacturing process, the mat 30 is formed by blending reinforcing fibers and a fibrous thermoplastic resin into a mat. As the blending method, for example, a dry blending method such as an air lay method or a card method can be used. In addition, although a wet blending method may be used as the blending method, when the reinforcing fiber has water absorption, a dry blending method is preferable.

(Supply process)
Next, as shown in FIG. 3, the mat 30 is placed on the conveyor 40, and the thermally expandable capsule 34 is supplied from the hopper 41 to the upper surface of the mat 30. As shown in FIG. 4, the supply port 42 of the hopper 41 extends in one side direction (vertical direction in FIG. 4) of the mat 30 having a rectangular shape.

  Thereby, the thermal expansion capsule 34 is dropped from the supply port 42 of the hopper 41, and the mat 30 is transported in the other side direction (right direction in FIG. 4) by the conveyor 40, so that the thermal expansion property is applied to the entire surface of the mat 30. A capsule 34 can be supplied.

  Further, as shown in FIG. 4, the opening width of the supply port 42 of the hopper 41 is the other end 42B (trim board) compared to the one end 42A (corresponding to the upper portion Y1 of the trim board 11) in the one side direction of the mat 30. 11 corresponding to the lower portion Y2) is smaller.

  As a result, the amount of the thermally expandable capsule 34 supplied to the portion of the mat 30 corresponding to the lower portion Y2 of the trim board 11 is smaller than that of the portion corresponding to the upper portion Y1 of the trim board 11. Thereby, the compounding quantity of the thermally expansible capsule 34 in the lower part Y2 of the trim board 11 can be decreased compared with the upper part Y1. That is, in this supply process, the supply amount of the thermally expandable capsule 34 supplied to the trim board 11 is different depending on the portion of the trim board 11.

  Further, in the supply port 42 of the hopper 41, the opening width of the boundary portion between the one end portion 42A and the other end portion 42B is set so as to gradually decrease toward the other end portion 42B.

  For this reason, the situation where the compounding quantity of the thermally expansible capsule 34 changes rapidly in the boundary part of the upper part Y1 and the lower part Y2 of the trim board 11 can be suppressed. As a result, it is possible to suppress a situation where stress concentrates on the boundary portion between the upper portion Y1 and the lower portion Y2 in the trim board 11.

(Dispersion process)
In the dispersing step, as shown in FIG. 5, the upper surface of the mat 30 is pressed by a pressing means 45 such as a roller while the mat 30 with the thermally expandable capsule 34 supplied to the upper surface is conveyed by the conveyor 43. Thereby, the thermally expandable capsule 34 on the upper surface of the mat 30 is dispersed inside the mat 30. Moreover, the mat 30 may be vibrated from the lower surface by the vibration means 46 simultaneously with the pressing by the pressing means 45. In this case, as the vibration means 46, for example, an electromagnetic feeder or the like can be used.

(Melting process)
Next, as shown in FIG. 6, the mat 30 is heated and pressed using the press dies 48 and 49, thereby melting the thermoplastic resin contained in the mat 30 and forming the mat 30 into a board shape. When the thermoplastic resin is melted, the fibers included in the mat 30 are bound to each other.

  The mat 30 formed into a board shape may be called a preboard. The mat 30 can be easily transported by putting it in a pre-board state.

(Expansion process)
Next, as shown in FIG. 7, the mat 30 is heated by, for example, a pair of infrared heaters 51 and 52 (heating device). Thereby, the thermally expandable capsule 34 inside the mat 30 expands by being heated. Further, the heated mat 30 is in a softened state. Instead of the pair of infrared heaters 51 and 52, a heating furnace that heats the mat 30 with hot air may be used.

(Molding process)
Next, as shown in FIG. 8, the softened mat 30 is pressed by a pair of molds 53 and 54. Thereby, the mat 30 is formed into a shape that follows the shape of the mold surfaces of the forming dies 53 and 54, and the trim board 11 is completed.

  Next, the effect of this embodiment will be described. According to the present embodiment, the thermally expandable capsule 34 is formed by making the blending amount of the thermally expandable capsule 34 in the lower portion Y2 of the trim board smaller than the blending amount of the thermally expandable capsule 34 in the upper portion Y1 of the trim board. Compared to the configuration in which the upper Y1 and the lower Y2 are blended at a uniform ratio, the amount of the thermally expandable capsule 34 used can be reduced, and the manufacturing cost can be reduced.

  In the above configuration, the lower portion Y2 of the trim board 11 includes a main surface portion 22A constituting the main surface of the trim board 11, and a standing wall portion rising from the peripheral end portion of the main surface portion 22A to the back side (one in the thickness direction of the main surface portion). 22B.

  Since the lower portion Y2 of the trim board 11 has the standing wall portion 22B, the rigidity is higher than, for example, a flat plate shape having no standing wall portion. For this reason, even if it is a case where the compounding quantity of the thermally expansible capsule 34 of the lower part Y2 is decreased, rigidity can be ensured.

  A silencer pad 26 is attached to the outer surface of the trim board 11 in the passenger compartment.

  Since the silencer pad 26 is attached along the outer side surface of the trim board 11, the rigidity of the lower portion Y <b> 2 is particularly increased. For this reason, even if it is a case where the compounding quantity of the thermally expansible capsule 34 of the lower part Y2 is decreased, rigidity can be ensured.

  The above effect will be described in detail with reference to FIG. FIG. 9 is a graph showing the results of measuring the maximum bending load in the trim boards of the present embodiment and the comparative example.

  The maximum bending load shown in FIG. 9 is measured by performing a three-point bending test based on JIS K7017. Further, the maximum bending load shown in FIG. 9 indicates the maximum bending load when the maximum bending load (reference value) required for the trim board is 100%.

  In FIG. 9, the following measurement results (A) to (F) are shown. Measurement results (A), (C), and (E) are measurement results of the present embodiment, and measurement results (B), (D), and (F) are measurement results of the comparative example. Moreover, the measurement location of the maximum bending load is illustrated by points P1 to P3 in FIG.

(A): Maximum bending load at the upper portion Y1 (measured at point P1 in FIG. 1) of the trim board 11 when the amount of the thermally expandable capsule is 6 parts by mass (B): the amount of the thermally expandable capsule The maximum bending load (C) at the lower portion Y2 of the trim board 11 (measured at point P2 in FIG. 1) when the amount is 6 parts by mass: The trim board 11 when the amount of the thermally expandable capsule is 4 parts by mass Maximum bending load (D) at lower part Y2 (measured at point P2 in FIG. 1): Lower part Y2 of trim board 11 (at point P3 in FIG. 1) when the amount of thermally expandable capsules is 6 parts by mass Maximum bending load (E) in measurement): Maximum bending load (F) in the lower portion Y2 (measured at point P3 in FIG. 1) of the trim board 11 when the blending amount of the thermally expandable capsule is 4 parts by mass: heat The amount of the expandable capsule is 4 parts by mass Maximum bending load in the upper Y1 (measured at the point P1 in FIG. 1) of the trim board 11 in the case

  According to Comparative Examples (B) and (D) of FIG. 9, the maximum bending load at the lower portion Y2 of the trim board 11 when the blending amount of the thermally expandable capsule is 6 parts by mass exceeds 130% of the reference value. Greatly exceeding the maximum bending load required for the trim board. However, there is a concern that the amount of thermally expandable capsules increases and the cost increases.

  So, in this embodiment, in the lower part Y2 of the trim board 11, the compounding quantity of the thermally expansible capsule was 4 mass parts, for example. According to FIGS. 9C and 9E, even when the blending amount of the thermally expandable capsule is 4 parts by mass, the maximum bending load required for the trim board is exceeded. That is, it is possible to reduce the amount of use of the thermally expandable capsule while ensuring the rigidity required for the trim board.

  Further, according to FIG. 9F, in the upper portion Y1 of the trim board 11, when the blending amount of the thermally expandable capsule is 4 parts by mass, the maximum bending load is required for the trim board 11. It became smaller than the value. For this reason, in the upper part Y1 of the trim board 11, the blending amount of the thermally expandable capsule is 6 parts by mass, and the maximum bending load is greater than the value required for the trim board 11 as shown in FIG. Also try to get bigger.

  As described above, in the present embodiment, in the trim board 11, the blending amount of the thermally expandable capsule is reduced in the portion where the rigidity is increased due to the shape and the attached member (second predetermined portion). . As a result, the use amount of the thermally expandable capsule can be reduced, and the manufacturing cost can be reduced.

  Further, in the present embodiment, the first predetermined portion constitutes the upper portion Y1 of the trim board 11, and the second predetermined portion constitutes the lower portion Y2 of the trim board 11.

  In many cases, the lower portion Y2 of the trim board 11 generally has a complicated shape (for example, the bulging portion 21). Further, in the lower part Y <b> 2 of the trim board 11, attached parts such as the door pocket 20, the silencer pad 26, a speaker (not shown) attached to the back side of the speaker grill 15 are often attached.

  For this reason, the lower portion Y2 of the trim board 11 is likely to have higher rigidity than the upper portion Y1. For this reason, even if it is a case where the compounding quantity of the thermally expansible capsule 34 in the lower part Y2 of the trim board 11 is decreased, it is easy to ensure rigidity.

<Other embodiments>
The present invention is not limited to the embodiments described with reference to the above description and drawings. For example, the following embodiments are also included in the technical scope of the present invention.

  (1) In the said embodiment, although the trim board 11 was illustrated as a fiber board, it is not limited to this. Examples of the fiber board include vehicle interior materials (deck board, package tray, quarter trim, deck side trim, trunk trim, pillar garnish, etc.) other than trim boards. The use of the fiber board is not limited to the vehicle interior material.

  (2) In the above embodiment, the upper portion Y1 of the trim board 11 is the first predetermined portion and the lower portion Y2 of the trim board 11 is the second predetermined portion. However, the present invention is not limited to this. The trim board 11 only needs to include an arbitrary predetermined portion (first predetermined portion) and a portion (second predetermined portion) in which the amount of thermally expandable capsules is smaller than that of the predetermined portion. Further, if the blending amount of the thermally expandable capsule is the same value in the first predetermined part and the second predetermined part, the rigidity (maximum bending load) of the first predetermined part is the rigidity of the second predetermined part. Lower than.

  (3) In the above-described embodiment, the configuration in which the bulging portion 21 bulges to the front side of the trim board 11 is exemplified, but the present invention is not limited to this. The bulging portion 21 only needs to bulge in one of the thickness directions of the trim board 11. The bulging part 21 may be bulged on the back side, for example. In other words, the standing wall portion 22B may rise from the peripheral end portion of the main surface portion 22A to the front side of the main surface portion 22A.

  (4) In the said embodiment, although the silencer pad 26 was illustrated as a to-be-attached component, it is not limited to this. The attached component may be any component that increases the rigidity of the trim board 11 by being attached to the trim board 11.

  (5) In the above embodiment, the amount of thermally expandable capsules in the trim board 11 is changed by partially changing the opening width of the supply port 42 of the hopper 41 by using one type of hopper 41 in the supplying step. Although the method of changing partially was illustrated, it is not limited to this. For example, the blending amount of the thermally expandable capsule may be partially changed by using two types of hoppers having different opening widths of the supply port. Further, the method for supplying the thermally expandable capsule is not limited to the one using the hopper 41. For example, the thermally expandable capsule may be supplied to the surface of the mat 30 by using an electrostatic coating method or an air current.

  (6) In the dispersion step of the above embodiment, the method of dispersing the thermally expandable capsules 34 inside the mat 30 using the pressing means 45 is exemplified, but the present invention is not limited to this. For example, the heat-expandable capsules 34 may be dispersed by arranging the heat-expandable capsules 34 between the two layers of mats and then interlacing the two layers of mats.

  (7) In the above embodiment, the melting step and the expansion step are separate steps, but the melting step and the expansion step may be performed in the same step. That is, in the melting step, the thermally expandable capsule 34 may be expanded when the mat 30 is heated and pressed. Further, the expansion process may be performed before the melting process.

DESCRIPTION OF SYMBOLS 10 ... Door trim (vehicle interior material) for vehicles, 11 ... Trim board (fiber board), 22A ... Main surface part, 22B ... Standing wall part, 26 ... Silencer pad (attachment parts), 34 ... Thermal expansion capsule, Y1 ... Upper part of trim board (first predetermined part), Y2 ... Lower part of trim board (second predetermined part)

Claims (5)

A fiber board comprising a fiber, a thermoplastic resin, and a thermally expandable capsule,
A first predetermined part;
A fiber board provided with the 2nd predetermined part which is a part with few compounding quantities of the thermally expansible capsule compared with the 1st predetermined part. The second predetermined part is:
A main surface portion constituting the main surface of the fiber board;
The fiber board according to claim 1, further comprising: a standing wall portion that rises from a peripheral end portion of the main surface portion to one side in a plate thickness direction of the main surface portion.   The fiber board according to claim 1 or 2, wherein a part to be attached is attached to the second predetermined portion.   The fiber board according to any one of claims 1 to 3, wherein the fiber board is an interior material for a vehicle. The fiber board is a trim board constituting a vehicle door trim,
The first predetermined portion constitutes an upper portion of the trim board,
The fiber board according to any one of claims 1 to 4, wherein the second predetermined portion constitutes a lower portion of the trim board.

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