JP2018122796A - Base material for interior part, interior part and method for producing them - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a base material for interior part capable of achieving improvement of a mechanical strength by novel structure and method and a method for producing the same, and to provide an interior part using the base material for interior part and a method for producing the same.SOLUTION: A base material 11 for interior part has a base layer 13 containing a reinforcement fiber 131 and a first thermoplastic resin 133 binding the reinforcement fibers, and a sewing thread 15 sewn so as to penetrate one surface and of an opposite surface to the one surface of the base layer, where the sewing thread 15 forms a first sewing pattern 153 and a second sewing pattern 155, the first sewing pattern 153 has a plurality of sewing patterns oriented in a predetermined direction, and the second sewing pattern 155 has a plurality of sewing patterns crossing the first sewing pattern. A needle hole 14 to which the sewing thread 15 is inserted is blocked by the melted and solidified first thermoplastic resin 133. An interior part has a base material 11 for interior part, and a skin layer laminated one surface side and/or opposite surface of the base material 11 for interior part.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a base material for interior parts, an interior part, and a method for producing them. More specifically, the present invention relates to an interior part base material formed by binding reinforcing fibers using a thermoplastic resin and a manufacturing method thereof, and an interior part using the interior part base material and a manufacturing method thereof.

For interior parts such as door trims and instrument panels, a base material for interior parts in which reinforcing fibers are bound by a thermoplastic resin can be used as the base material. The interior component base material is required to have many characteristics. For example, it is lightweight, can be thinned, has formability, is thin and lightweight, has high mechanical strength, can be applied with an epidermis, does not hinder the design of the epidermis, and the plant fiber is reinforced fiber And the like. By balancing such characteristics, for example, to obtain interior parts that have design characteristics as interior parts, have strength as structural parts, and also have environmental characteristics that can be compatible with carbon neutral. Can do.
In addition, the following patent document 1 and the following patent document 2 are known as a technique which sews with respect to interior components.

JP, 2015-160484, A Japanese Patent Laying-Open No. 2015-093601

Conventionally, the base material for interior parts has, for example, mechanical strength by selecting the type of reinforcing fiber, selecting the type of thermoplastic resin that binds the reinforcing fiber, and strengthening the binding force by changing the chemical structure of the thermoplastic resin. Improvements have been made. However, the operation of these various options makes it difficult to achieve further dramatic functional improvements. However, there is a need for further improvement in mechanical strength, and there is a need for improvement in mechanical strength from a point of view that is not present in the past while balancing the various characteristics described above.
The above Patent Document 1 and Patent Document 2 are techniques that utilize stitches by sewing as a design pattern, but are not configured to improve mechanical strength, and have no such attention, even if the effect is recognized. Absent.

  The present invention has been made in view of the above circumstances, and is a base material for interior parts that can improve mechanical strength, and a method for manufacturing the same, and an interior that uses the base material for interior parts. An object is to provide a component and a method for manufacturing the component.

That is, the present invention is as follows.
[1] The base material for interior parts according to claim 1 includes a base layer including a reinforcing fiber and a first thermoplastic resin binding the reinforcing fibers;
Having one surface of the base layer and a sewing thread that is sewn through the opposite surface;
The sewing thread forms a first sewing pattern and a second sewing pattern,
The first sewing pattern has a plurality of sewing patterns oriented in a predetermined direction,
The second sewing pattern has a plurality of sewing patterns intersecting the first sewing pattern,
The gist is that the needle hole through which the sewing thread is inserted is closed by the melted and solidified first thermoplastic resin.
[2] The base material for interior parts according to claim 2 includes a base layer including a reinforcing fiber and a first thermoplastic resin that binds the reinforcing fibers to each other;
A sewing thread sewn inside the base layer without penetrating through at least one of the one surface and the opposite surface of the base layer;
The sewing thread forms a first sewing pattern and a second sewing pattern,
The first sewing pattern has a plurality of sewing patterns oriented in a predetermined direction,
The second sewing pattern has a plurality of sewing patterns intersecting the first sewing pattern,
The gist is that the needle hole through which the sewing thread is inserted is closed by the melted and solidified first thermoplastic resin.
[3] A base material for interior parts according to claim 3 is the base material for interior parts according to claim 1 or 2, wherein the fineness of the sewing thread is 500 dtex or more and 1300 dtex or less.
[4] The interior part base material according to claim 4 is the interior part base material according to any one of claims 1 to 3, wherein the sewing thread includes a second thermoplastic resin,
The gist is that the second thermoplastic resin is melted and solidified in the needle hole.
[5] The interior component according to claim 5 is the interior component base material according to any one of claims 1 to 4,
The gist is to have a skin layer laminated on one side and / or the opposite side of the interior component base material.
[6] The method for manufacturing a base material for interior parts according to claim 4 is the method for manufacturing a base material for interior parts according to claim 1,
A sewing step of forming the first sewing pattern and the second sewing pattern on a fiber reinforced board compressed including the reinforcing fiber and the first thermoplastic resin;
And a shaping step of shaping the fiber reinforced board on which the first sewing pattern and the second sewing pattern are formed.
[7] A method for manufacturing a base material for interior parts according to claim 7 is the method for manufacturing a base material for interior parts according to claim 1,
A sewing step of forming the first sewing pattern and the second sewing pattern on a mixed mat of the reinforcing fibers and the resin fibers made of the first thermoplastic resin;
A compression step of obtaining a fiber reinforced board by compressing the mixed fiber mat formed with the first sewing pattern and the second sewing pattern;
And a shaping step of shaping the fiber reinforced board.
[8] The method for manufacturing a base material for interior parts according to claim 8 is the method for manufacturing a base material for interior parts according to claim 2,
A sewing step of forming the first sewing pattern and the second sewing pattern on a mixed mat of the reinforcing fibers and the resin fibers made of the first thermoplastic resin;
A mixed fiber layer including the reinforcing fiber and the resin fiber made of the first thermoplastic resin is provided on one side and / or the opposite side of the mixed fiber mat on which the first sewing pattern and the second sewing pattern are formed. An additional layering process for additional layering;
A compression step of obtaining a fiber reinforced board by compressing a mixed fiber mat additionally laminated with the mixed fiber layer;
And a shaping step of shaping the fiber reinforced board.
[9] The method for manufacturing a base material for interior parts according to claim 9 is the method for manufacturing a base material for interior parts according to any one of claims 6 to 8, wherein the sewing thread is a second heat. When plastic resin is included,
The gist is that the second thermoplastic resin is heated and melted to heat and melt the second thermoplastic resin.
[10] A method for manufacturing an interior part according to claim 10 is the method for manufacturing an interior part according to claim 5,
After the shaping step in the method for producing a base material for interior parts according to any one of claims 6 to 8,
The gist is to provide a skin layer laminating step of laminating a skin layer on one side and / or the opposite side of the shaped fiber reinforced board.

The base material for interior parts of the present invention has a plurality of sewing patterns intersecting each other, which are a first sewing pattern and a second sewing pattern.
Thereby, an improvement in mechanical strength can be realized. That is, without changing the configuration of the base material for interior parts (for example, changing the reinforcing fiber, changing the binder resin, etc.) balanced so that each characteristic is skillfully expressed, or with these configuration changes Separately, the mechanical strength can be reinforced by the first sewing pattern and the second sewing pattern.
Further, in the interior component base material, the needle hole through which the sewing thread is inserted is closed by the melted and solidified first thermoplastic resin, so that the machine is more mechanical than the non-closed interior component base material. Strength can be increased.
The interior component of the present invention includes the interior component base material and a skin layer laminated on one surface side and / or the facing side of the interior component base material. Thereby, compared with the conventional interior component using the base material for interior components which does not have a 1st sewing pattern and a 2nd sewing pattern, higher mechanical strength can be obtained.

All the manufacturing methods (first to third manufacturing methods) of the base material for interior parts of the present invention include a sewing process for forming the first sewing pattern and the second sewing pattern, and fiber reinforcement in which these sewing patterns are formed. A shaping process for shaping the board.
Thereby, the base material for interior parts of this invention can be obtained. That is, it is possible to obtain an interior component base material having improved mechanical strength as compared with a conventional interior component base material that does not have the first sewing pattern and the second sewing pattern, and each characteristic is skillfully expressed. Without changing the configuration of the interior component base material that is balanced (for example, changing the reinforcing fiber, changing the binder resin, etc.) or separately from these configuration changes, The mechanical strength of can be reinforced.

The manufacturing method of the interior component of the present invention includes, in addition to the respective steps described in the above-described manufacturing method (first to third manufacturing methods) of the interior component base material, on one side and / or the opposite side of the fiber reinforced board. A skin layer laminating step for laminating the skin layer is provided.
Thereby, the interior component which has higher mechanical strength can be manufactured compared with the conventional interior component using the base material for interior components which does not have the 1st sewing pattern and the 2nd sewing pattern.

The present invention will be further described in the following detailed description with reference to the drawings referred to, with reference to non-limiting examples of exemplary embodiments according to the present invention. Similar parts are shown through several figures.
It is explanatory drawing explaining an example of the base material for interior components. It is explanatory drawing explaining the other example of this base material for interior components. It is explanatory drawing explaining an example of a sewing pattern. It is a top view explaining the other example of a sewing pattern. It is explanatory drawing explaining the other example of a sewing pattern. It is a top view explaining the other example of a sewing pattern. It is a top view explaining the other example of a sewing pattern. It is a fragmentary sectional view showing typically an example of the substrate for interior parts. It is a fragmentary sectional view showing other examples of this interior parts base material typically. It is a fragmentary sectional view showing other examples of this interior parts base material typically. It is a fragmentary sectional view showing typically an example of this interior part. It is a fragmentary sectional view showing other examples of this interior part typically. It is explanatory drawing explaining an example (1st manufacturing method) of the manufacturing method of this base material for interior components. It is explanatory drawing explaining the other example (2nd manufacturing method) of the manufacturing method of this base material for interior components. It is explanatory drawing explaining the other example (3rd manufacturing method) of the manufacturing method of this base material for interior components. It is explanatory drawing explaining the skin layer lamination | stacking process in the manufacturing method of this interior component.

  The items shown here are exemplary and illustrative of the embodiments of the present invention, and are the most effective and easy-to-understand explanations of the principles and conceptual features of the present invention. It is stated for the purpose of providing what seems to be. In this respect, it is not intended to illustrate the structural details of the present invention beyond what is necessary for a fundamental understanding of the present invention. It will be clear to those skilled in the art how it is actually implemented.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
1A is a plan view of the one surface 13a side of the base layer 13. FIG. Further, (b) is a sectional view taken along line ZZ ′ in (a). FIG. 6C is a partially enlarged view showing the vicinity of the sewing thread 15 in FIG. FIG. 4D is an enlarged view schematically showing the reinforcing fiber 131 and the first thermoplastic resin 133 constituting the base layer 13.
The interior component base material 11 shown in FIG. 1 exemplifies a form without the additional layer 135.

2A is a plan view (partially transparent view) on the one surface 13a side of the base layer 13. FIG. Further, (b) is a sectional view taken along line ZZ ′ in (a). FIG. 6C is a partially enlarged view showing the vicinity of the sewing thread 15 in FIG. FIG. 4D is an enlarged view schematically showing the reinforcing fiber 131 and the first thermoplastic resin 133 constituting the base layer 13.
The base material 11 for interior parts shown in FIG. 2 exemplifies a form having an additional layer 135. In FIG. 2A, since the sewing pattern 151 is located below the additional layer 135, the sewing pattern 151 is a transparent view.

3A is a plan view for explaining an example of the sewing pattern, and FIG. 3B is a diagram showing a modification of the first sewing pattern 153 among the sewing patterns of FIG. FIG. 5 is a plan view showing only one sewing pattern 153 extracted.
5A is a plan view for explaining another example of the sewing pattern, and FIG. 5B shows only the first sewing pattern 153 extracted from the sewing patterns of FIG. 5A. FIG. 8C is a plan view showing only the second sewing pattern 155 extracted from the sewing patterns shown in FIG.

[1] Base material for interior parts The base material for interior parts (11) (see FIGS. 1 and 8) according to the first aspect of the present invention has a reinforcing fiber (131) and a reinforcing fiber (131) bonded together. A base layer (13) containing 1 thermoplastic resin (133);
A sewing thread (15) sewn through one surface (13a) of the base layer (13) and the opposite surface (13b);
The sewing thread (15) forms a first sewing pattern (153) and a second sewing pattern (155),
The first sewing pattern (153) has a plurality of sewing patterns oriented in a predetermined direction,
The second sewing pattern (155) has a plurality of sewing patterns intersecting the first sewing pattern (153),
The needle hole (14) through which the sewing thread (15) is inserted is closed by the melted and solidified first thermoplastic resin (133).

On the other hand, the interior component base material (11) according to the second invention (see FIGS. 2, 9, and 10) is a first thermoplastic resin that binds the reinforcing fibers (131) and the reinforcing fibers (131). A base layer (13) containing a resin (133);
A sewing thread (15) sewn inside the base layer (13) without penetrating through at least one of the one surface (13a) and the opposite surface (13b) of the base layer (13),
The sewing thread (15) forms a first sewing pattern (153) and a second sewing pattern (155),
The first sewing pattern (153) has a plurality of sewing patterns oriented in a predetermined direction,
The second sewing pattern (155) has a plurality of sewing patterns intersecting the first sewing pattern (153),
The needle hole (14) through which the sewing thread (15) is inserted is closed by the melted and solidified first thermoplastic resin (133).

In the interior part base material 11 of the first invention and the interior part base material 11 of the second invention, the sewing thread 15 penetrates the base layer 13 or the sewing thread 15 penetrates the base layer 13. Without being disposed inside the base layer 13.
As shown in the manufacturing method described later, among these, the interior component base material 11 of the first invention is provided with a sewing pattern on the mixed fiber mat 13s and the fiber reinforced board 13t, and after applying necessary processing thereto. Can be obtained by shaping. On the other hand, the base material 11 for interior parts of the second invention, after providing a sewing pattern to the mixed fiber mat 13s, after additionally laminating a mixed fiber layer on at least one surface of the mixed fiber mat 13s, Further, it can be obtained by performing necessary processing such as forming on a fiber reinforced board and then shaping.
In contrast to the interior component base material 11 of the first invention, the interior component base material 11 of the second invention can have a surface on which the sewing thread 15 is not exposed. It is possible to prevent the unevenness caused by the sewing thread 15 from affecting the design surface 12 a of the interior part 1.

The form of the base layer 13 is not limited, but can be plate-shaped. That is, it is a layer having a substantially uniform thickness as a whole, and an uneven shape can be imparted if necessary.
The base layer 13 is obtained by, for example, heating and compressing a mixed mat 13s (a mixture of fibers in a mat shape) of reinforcing fibers 131 and fibers (resin fibers) formed from the first thermoplastic resin 133. Can be obtained. More specifically, for example, the mixed fiber mat 13s including the reinforcing fiber 131 and the resin fiber 133 ′ made of the first thermoplastic resin (hereinafter also simply referred to as “first thermoplastic resin fiber”) is heated. After obtaining the fiber reinforced board 13t (precursor of the base layer 13) by compressing, further necessary processing is performed, and the first thermoplastic resin 133 is heated and softened again. However, the base layer 13 can be formed by shaping.

Further, the interior component base material 11 has a first sewing pattern 153 and a second sewing pattern 155 formed by the sewing thread 15, and the needle hole 14 through which the sewing thread 15 constituting the sewing pattern is inserted. The first thermoplastic resin 133 is melted and solidified.
Thus, by having the crossed sewing patterns (in this specification, the first sewing pattern 153 and the second sewing pattern 155 are also simply referred to as “sewing pattern” (151)), The mechanical strength of the material 11 can be improved. Although it is not clear how the mechanical strength is improved by having the crossed sewing patterns, for example, the bending elastic modulus can be greatly improved. That is, mechanical strength reinforcement can be performed by sewing without changing the configuration of the interior part base material 11 balanced so that each characteristic can be skillfully expressed, or separately from these configuration changes. Further, since the first sewing pattern 153 is oriented, the crossing points are dispersed regardless of the orientation of the second sewing pattern, and the deviation of reinforcement in the interior component base material 11 to be obtained is suppressed. It is thought that.

However, it is usually difficult to improve the mechanical strength by sewing as described above. For example, when sewing is performed on the board, a needle hole is generated by the penetration of the sewing needle. Such a needle hole becomes a starting point for fracture because the inside is hollow. Therefore, when line-shaped sewing is performed, the fracture starting points are arranged in a line, and the strength decreases along the sewing line.
On the other hand, the interior component base material 11 is closed by the first thermoplastic resin in which the needle holes 14 are melted and solidified. This is possible because the base layer 13 of the interior component base material 11 is a base layer including the reinforcing fibers 131 and the first thermoplastic resin 133. That is, the base layer 13 is formed in the form of a fiber reinforced board 13t including the reinforcing fiber 131 and the first thermoplastic resin 133 or a mixture of the reinforcing fiber 131 and the resin fiber 133 ′ made of the first thermoplastic resin. The form of the fine mat 13s and the form that can be sewn before shaping can be passed. Therefore, in these forms before shaping, the needle hole 14 can be closed by the first thermoplastic resin 133 constituting the base layer 13 by performing shaping after sewing. That is, the first thermoplastic resin 133 can be brought into close contact with the sewing thread 15 provided on the base layer 13, and the needle hole 14 can be prevented from remaining hollow.

  In the present invention, the sewing pattern (the first sewing pattern, the second sewing pattern, etc.) may be applied to only a part of the interior component base material 11 or the entire interior component base material 11 (entire surface). ). The sewing pattern may be provided only at one location of the interior component base material 11 or may be provided at a plurality of locations of the interior component base material 11.

The kind of the reinforcing fiber 131 constituting the base layer 13 is not limited, and inorganic fiber (glass fiber or the like) or organic fiber (natural fiber such as plant fiber or animal fiber) can be used. These may use only 1 type and may use 2 or more types together.
Of these, organic fibers are preferable, natural fibers are more preferable, and plant fibers are particularly preferable. Plant fiber is a fiber derived from a plant, and includes a fiber taken out from a plant and a fiber obtained by processing the fiber. Plant fibers include leaf vein plant fibers, bast plant fibers, woody plant fibers, and other plant fibers. These may use only 1 type and may use 2 or more types together.
Among these, examples of leaf vein plant fibers include abaca, sisal, agave and the like. Examples of bast plant fibers include flux, jute, hemp, kenaf, ramie and the like. Furthermore, examples of the woody plant fibers include plant fibers collected from broad-leaved trees and conifers. Examples of other plant fibers include coconut shell fiber, oil palm empty fruit bunch fiber, rice straw fiber, wheat straw fiber, bamboo fiber, and cotton. Among these, leaf type plant fibers, bast plant fibers and other plant fibers are preferable.

  The fiber length of the reinforcing fiber is not particularly limited, but the average fiber length can be 10 to 200 mm (further 20 to 170 mm, particularly 30 to 150 mm). This average fiber length is based on JIS L1015. Single fibers are taken out one at a time by the direct method, stretched straight without stretching, and the fiber length is measured on a measuring scale. It is the average value of the measured values.

  The kind of 1st thermoplastic resin 133 is not limited, Various thermoplastic resins can be utilized. Specific examples include polyolefin resins, polyester resins, polystyrene resins, acrylic resins, polyamide resins, polycarbonate resins, polyacetal resins, and ABS resins. These may use only 1 type and may use 2 or more types together.

Among the above, the first thermoplastic resin is preferably a polyolefin resin. Examples of the olefin monomer constituting the polyolefin resin include ethylene, propylene, 1-butene, 3-methyl-1-butene, 1-pentene, 3-methyl-1-pentene, 4-methyl-1-pentene, 1- Examples include hexene and 1-octene. These may use only 1 type and may use 2 or more types together.
That is, examples of the polyolefin resin include polyethylene resins such as an ethylene homopolymer, an ethylene / 1-butene copolymer, an ethylene / 1-hexene copolymer, and an ethylene / 4-methyl-1-pentene copolymer. . These polyethylene resins are resins whose units are derived from ethylene by 50% or more of the total number of structural units. Furthermore, polypropylene resins such as propylene homopolymer, propylene / ethylene copolymer (propylene / ethylene random copolymer, etc.), propylene / 1-butene copolymer and the like can be mentioned. These polypropylene resins are resins whose units are derived from propylene by 50% or more of the total number of structural units.

The first thermoplastic resin may be only a non-modified thermoplastic resin, or may include a thermoplastic resin modified by introducing a polar group. Examples of polar groups include carboxylic anhydride groups (—CO—O—OC—), carboxylic acid groups (—COOH), carbonyl groups (—CO—), hydroxyl groups (—OH), amino groups (—NH ₂ ), a nitro group _(-NO 2), a nitrile group (-CN) and the like. These may use only 1 type and may use 2 or more types together.

  The ratio of the reinforcing fibers 131 and the first thermoplastic resin 133 included in the base layer 13 is not limited, but the ratio of the reinforcing fibers 131 when the total of the reinforcing fibers 131 and the first thermoplastic resin 133 is 100% by mass. Can be 10 mass% or more and 90 mass% or less, 15 mass% or more and 85 mass% or less are preferable, 15 mass% or more and 85 mass% or less are more preferable, 20 mass% or more and 80 mass% or less are still more preferable. 25 mass% or more and 75 mass% or less is still more preferable, 30 mass% or more and 70 mass% or less are especially preferable, 35 mass% or more and 65 mass% or less are more preferable, and 40 mass% or more and 60 mass% or less are especially preferable. .

The sewing thread 15 includes a first sewing pattern 153 that is a plurality of sewing patterns oriented in a predetermined direction, and a second sewing pattern 155 that is a plurality of sewing patterns intersecting the first sewing pattern 153. Forming.
In the interior part base material 11 of the first invention, since it is actually a sewing needle that “sews through” one surface 13 a and the opposite surface 13 b of the base layer 13, one sewing thread 15 is provided. It does not matter whether the substrate 13 penetrates alone. Similarly, in the interior part base material 11 of the second invention, whether the sewing thread 15 penetrates the base layer 134 of the base layer 13 and one sewing thread 15 passes through the base layer 13 alone. It doesn't matter.
For example, when using the upper thread 15a and the lower thread 15b, as shown in FIGS. 8 to 10, the upper thread 15a is provided on the one surface 13a side of the base layer 13, and the lower thread 15b is provided on the facing surface 13b side. In this case, the upper thread 15a is drawn into the needle hole 14 from the one surface 13a side, does not penetrate the base layer 13, is entangled with the lower thread 15b and pulled out to the one surface 13a side. Similarly, the lower thread 15b is pulled from the facing surface 13b side. Although it is drawn into the needle hole 14 and does not penetrate the base layer 13, it is entangled with the upper thread 15a and pulled out to the facing side 13b, and each of the upper thread 15a and the lower thread 15b alone does not penetrate the base layer 13, The sewing thread 15 as a whole can be in a state of penetrating the base layer 13 or a state of penetrating the base layer 134 of the base layer 13.

  Only one sewing thread 15 or a plurality of sewing threads 15 may be used. Usually, a plurality of sewing threads 15 are used. Specifically, for example, two of an upper thread 15a and a lower thread 15b can be used (see FIGS. 8 to 10). In addition, for example, a sewing thread forming a first sewing pattern and a sewing thread forming a second sewing pattern can be included. Furthermore, for example, when the first sewing pattern is formed from a plurality of sewing threads and the second sewing pattern is formed from a plurality of sewing threads, a larger number of sewing threads can be used. That is, the sewing thread 15 can use a suitable number appropriately selected depending on the sewing form and the sewing pattern.

The sewing thread 15 may be a filament yarn having a long fiber structure (continuous long fibers), a spun yarn having a structure in which short fibers are twisted together, or a combination thereof. Among these, a filament yarn is preferable from the viewpoint of strength.
The sewing thread 15 may be a monofilament, a multifilament, or a combination thereof. Among these, it is preferable to use a multifilament from the viewpoint of flexibility.
Furthermore, the sewing thread 15 may be a twisted thread, a non-twisted thread, or a combination thereof.

The material which comprises the sewing thread | yarn 15 is not limited, Resin fiber, carbon fiber, a metal fiber, etc. can be utilized. These may use only 1 type and may use 2 or more types together. Among these, resin fibers are preferable from the viewpoints of flexibility and strength. That is, the resin fiber can achieve both excellent flexibility and excellent strength.
The kind of resin constituting the resin fiber is not limited. For example, a polyparaphenylene benzobisoxazole resin, a polyester resin, a polyamide resin, a polyphenylene sulfide resin, a polyether ketone resin, a polyimide resin, a polyolefin resin, a thermoplastic resin, a fluorine resin, and the like can be given. These may use only 1 type and may use 2 or more types together.

Among the above, as the polyester resin, polyalkylene terephthalate (polyethylene terephthalate, polybutylene terephthalate, etc.), polyalkylene naphthalate, liquid crystal polymer (polycondensation resin of ethylene terephthalate and parahydroxybenzoic acid, phenol, phthalic acid and parahydroxy) Polycondensation resin with benzoic acid, polycondensation resin with 2,6-hydroxynaphthoic acid and parahydroxybenzoic acid, etc., polyarylate (polycondensation with dihydric phenol and dibasic acid (phthalic acid, carboxylic acid, etc.) Resin).
Examples of the polyamide resin include aliphatic polyamide resins and aromatic polyamide resins. Of these, examples of the aliphatic polyamide resin include nylon 6, nylon 66, nylon 11, and the like. On the other hand, an aromatic polyamide resin includes an aramid resin. Furthermore, examples of the aramid resin include para-type aramid resins (copolyparaphenylene, 3,4'-oxydiphenylene terephthalamide, polyparaphenylene terephthalamide, etc.), and meta-type aramid resins (polymetaphenylene isophthalamide). It is done.
Furthermore, aromatic polyether ketone resin is mentioned as polyether ketone resin. More specifically, polyetherketone (PEK), polyetheretherketone (PEEK), polyetherketoneketone (PEKK), polyetheretherketoneketone (PEEKK) and the like can be mentioned.
Examples of the polyolefin resin include a high-strength polyethylene resin. Furthermore, polyvinylidene fluoride etc. are mentioned as a thermoplastic resin fluororesin.
Each of these resins may be used alone or in combination of two or more.

  More specifically, polyparaphenylene benzobisoxazole fibers such as trade name “Zylon” (registered trademark / Toyobo Co., Ltd.), trade name “Kevlar” (registered trademark / Ei Dupont de Nemours & Co., Ltd.) Company), product name “Technora” (registered trademark / Teijin Ltd.), product name “Twaron” (registered trademark / Teijin Ltd.) and other para-aramid fibers, product name “Conex” (registered trademark / Teijin Ltd.) And meta-aramid fibers such as “Vectran” (registered trademark / Kuraray Co., Ltd.).

  The sewing thread 15 is particularly preferably a highly elastic thread and a thread having a high breaking strength. Although the specific breaking strength is not limited, for example, it is preferably 30 cN / dtex or more, more preferably 40 cN / dtex or more and 200 cN / dtex or less, further preferably 50 cN / dtex or more and 200 cN / dtex or less, more preferably 70 cN. / Dtex or more and 200 cN / dtex or less is particularly preferable. This breaking strength is based on the tensile strength (standard time test) of JIS L1013.

Further, the fineness of the sewing thread 15 is not limited, but can be, for example, 500 dtex or more and 1300 dtex or less. Further, it can be set to 570 dtex or more and 1250 dtex or less, and further can be set to 640 dtex or more and 1230 dtex or less.
When the sewing thread 15 is divided into the upper thread 15a and the lower thread 15b, the upper thread 15a and the lower thread 15b may use the same fineness or different finenesses. When using a different fineness, it is preferable to make the fineness of the upper thread 15a larger than the fineness of the lower thread 15b. In this case, the fineness of the upper thread 15a is preferably 850 dtex or more and 1300 dtex or less, more preferably 900 dtex or more and 1250 dtex or less, and particularly preferably 950 dtex or more and 1200 dtex or less. On the other hand, the fineness of the lower thread 15b is preferably 500 dtex or more and less than 850 dtex, more preferably 550 dtex or more and 825 dtex or less, and particularly preferably 600 dtex or more and 800 dtex or less.
In the case where the upper thread 15a and the lower thread 15b are used as the sewing thread 15, as will be described later, when the thread including the second thermoplastic resin is used, the upper thread 15a is made of the second thermoplastic resin. It is not included and can be used as a form in which the second thermoplastic resin is included only in the lower thread 15b.

  In the present invention, the sewing thread 15 can contain a second thermoplastic resin. That is, the second thermoplastic resin suitable for melting can be blended in the sewing thread 15. When the sewing thread 15 containing the second thermoplastic resin is used, the second thermoplastic resin contained in the sewing thread 15 can be melted and solidified after the sewing pattern is formed. At this time, all of the second thermoplastic resin may be melted or only a part thereof may be melted. When the second thermoplastic resin is melted and solidified, the sewing thread 15 can be made more accustomed to the base layer 13. That is, when the second thermoplastic resin is melted, the interface between the material constituting the base layer 13 and the material constituting the sewing thread 15 becomes complicated, and the interface between the materials becomes the starting point of fracture. As compared with the case where the second thermoplastic resin is not melted and solidified, the mechanical strength of the obtained interior component base material can be improved.

  The kind of 2nd thermoplastic resin contained in the sewing thread | yarn 15 is not limited, The various thermoplastic resin illustrated to the above-mentioned 1st thermoplastic resin can be utilized as it is. The first thermoplastic resin and the second thermoplastic resin may be the same or different from each other, but the first thermoplastic resin and the second thermoplastic resin are preferably resins having close melting temperatures. Thereby, when one thermoplastic resin is melted, the other thermoplastic resin can also be melted in the same step. Further, at the time of melting, the thermoplastic resins are easily adapted to each other, and the interface formation between the materials can be suppressed.

More specifically, the melting point of the first thermoplastic resin (if the melting point unknown melting start temperature, the unit "℃") was a T _1, when the melting point of the second thermoplastic resin (melting point unknown melting start temperature, if the unit "℃") was _{T 2,} preferably from _{-20 ≦ T 1 -T 2 ≦ 35} , and more preferably _{5 ≦ T 1 -T 2 ≦ 35} . In particular, when −20 ≦ T ₁ −T ₂ ≦ 35, particularly when −10 ≦ T ₁ −T ₂ ≦ 10, the first thermoplastic resin and the second thermoplastic resin can be melted together. It becomes possible. For this reason, the 1st thermoplastic resin which comprises the base layer 13 and the 2nd thermoplastic resin which comprises the sewing thread | yarn 15 can be united. In this case, the first thermoplastic resin and the second thermoplastic resin are both melted and solidified, and the formation of the interface between them can be suppressed.

Note that “T ₁ -T ₂ ” can be set to more than 35 ° C. when necessary regardless of the above. In this case, since only the second thermoplastic resin can be easily melted without melting the first thermoplastic resin, only the second thermoplastic resin is melted without affecting the base layer 13. be able to. Similarly, “T ₁ -T ₂ ” may be less than −20 ° C. In this case, since only the first thermoplastic resin can be easily melted without melting the second thermoplastic resin, only the first thermoplastic resin is melted without affecting the sewing thread 15. Can be made.

As described above, the sewing thread 15 containing the second thermoplastic resin may consist entirely of the second thermoplastic resin, but usually the structural fiber (melting / decomposing also when the second thermoplastic resin is melted). Not including fibers capable of maintaining the structure of the yarn) and the second thermoplastic resin.
This second thermoplastic resin may be contained in the sewing thread 15 in any manner. For example, the sewing thread 15 including the thermoplastic fibers made of the second thermoplastic resin together with the structural fibers can be used. Specifically, there is a sewing thread 15 in which a plurality of structural fiber yarns and a plurality of second thermoplastic resin fiber yarns are mixed and twisted. In this case, the second thermoplastic resin fiber yarn can be dispersed and disposed together with the structural fiber yarn, but can be disposed so as to surround the outside of the structural fiber yarn.
The sewing thread 15 can have a core-sheath structure. Specifically, a core sheath in which a sheath material made of a second thermoplastic resin is disposed on the outer periphery of a single structural fiber yarn (may be a monofilament or a multifilament). A sewing thread 15 having a structure can be obtained.

  Further, as a matter of course, in the sewing thread 15 including the structural fiber and the second thermoplastic resin, only the second thermoplastic resin (all or a part thereof) is melted by heating, and the structural fiber is not melted or decomposed. Is preferred. Therefore, when the structural fiber is formed from a thermoplastic resin, the thermoplastic resin (third thermoplastic resin) constituting the structural fiber is preferably a thermoplastic resin having a higher melting point than the second thermoplastic resin.

The first sewing pattern 153 is a plurality of sewing patterns oriented in a predetermined direction. The orientation refers to at least two sewing lines 153x (for example, see FIG. 1 and FIG. 2) having substantially uniform intervals (parallel lines, concentric circle lines, etc.), or line portions constituting the sewing line 153x (for example, , See FIG. 6B). The first sewing pattern 153 may be formed from one sewing line 153x, or may be formed from two or more sewing lines 153x.
The first sewing pattern 153 may be formed only from the sewing line 153x that is entirely oriented, but may have other forms. That is, the first sewing pattern 153 only needs to have a region in which the sewing line 153x is oriented, and the entire first sewing pattern 153 need not be formed only from the oriented sewing line 153x. A sewing line 153x in a non-oriented relationship may be included (see FIG. 3B).
The first sewing pattern 153 may be formed from one sewing thread or may be formed from a plurality of sewing threads. Further, the sewing thread forming the first sewing pattern 153 and the sewing thread forming the second sewing pattern 155 may be the same one sewing thread or different sewing threads. Also good.

On the other hand, the 2nd sewing pattern 155 should just cross | intersect the 1st sewing pattern 153, and the presence or absence of the orientation of the sewing lines 155y which comprise the 2nd sewing pattern 155 does not ask | require. That is, the second sewing pattern 155 may be oriented in a predetermined direction, but may not be oriented.
The second sewing pattern 155 may be formed from one sewing line 155y, or may be formed from two or more sewing lines 155y.
The second sewing pattern 155 may be formed from one sewing thread or a plurality of sewing threads. Further, the sewing thread forming the second sewing pattern 155 and the sewing thread forming the first sewing pattern 153 may be the same one sewing thread or different sewing threads. Also good.

  Regardless of whether the sewing line 153x that constitutes the first sewing pattern 153, the sewing line 155y that constitutes the second sewing pattern 155, or the other sewing line, This is a thread formed by sewing the sewing thread 15. The sewing line may be a continuous line, or may be intermittent as in the case of a dotted line but forming a line as a whole. Furthermore, the sewing line may be linear, curved, or other shapes. Moreover, the sewing line may be formed from one thread, or may be formed so as to form a sewing line as a whole by two or more (a plurality of) parallel threads.

  In addition, in the base material 11 for interior parts of 1st invention, these sewing patterns can be normally confirmed visually on both the one surface 11a and the opposing surface 11b. That is, since the sewing pattern is formed by the sewing thread 15 penetrating the front and back, the sewing pattern is exposed on both the one surface 11a and the opposite surface 11b. On the other hand, in the interior part base material 11 of the second invention, the sewing thread 15 is not exposed on one of the one surface 11a or the facing surface 11b or the sewing thread 15 is not exposed on both the one surface 11a and the facing surface 11b. Although not visible on the non-exposed surface, each sewing pattern is disposed at a predetermined depth from the non-exposed surface (see FIGS. 9 and 10).

As a concrete sewing pattern, the sewing pattern shown in FIGS. 3-7 is mentioned, for example. Only one kind of these sewing patterns may be included in the interior part base material 11 or two or more kinds may be simultaneously present.
The sewing pattern shown in FIG. 3A includes a first sewing pattern 153 formed as an assembly of a plurality of sewing lines 153x that are vertically oriented (arranged in parallel to the vertical direction), and the first sewing pattern 153. And a second sewing pattern 155 formed by an assembly of sewing lines 155y respectively intersecting with the sewing line 153x constituting the sewing pattern.
In the sewing pattern of FIG. 3A, the second sewing pattern 155 is formed by an assembly of a plurality of sewing lines 155y that are laterally oriented (arranged in parallel in the horizontal direction). The sewing pattern of a) is a form in which any pattern may be the first sewing pattern 153 and any pattern may be the second sewing pattern 155.
In FIG. 3A, the first sewing pattern 153 is formed only from the sewing lines 153x oriented to each other, but the first sewing pattern 153 can include a non-oriented portion. That is, the first sewing pattern 153 shown in FIG. 3 (b) is a pattern that can be replaced with the first sewing pattern 153 shown in FIG. 3 (a), and includes a region A in which the sewing lines 153x are oriented to each other, and a sewing Lines 153x have regions B that are not oriented with respect to each other. Thus, the 1st sewing pattern 153 should just have the orientation area | region A in at least one part. It should be noted that the first sewing pattern 153 can include a non-oriented portion in this manner as well as in the example patterns of other drawings.

The sewing pattern shown in FIG. 4 includes a first sewing pattern 153 formed as an aggregate of a plurality of sewing lines 153x that are concentrically oriented (concentrically arranged), and a sewing line 153x that constitutes the first sewing pattern 153. And a second sewing pattern 155 formed by an assembly of sewing lines 155y intersecting with each other.
In the sewing pattern of FIG. 4, the second sewing pattern 155 is formed by an assembly of a plurality of sewing lines 155y that are concentrically oriented (arranged concentrically). Therefore, the sewing pattern of FIG. This pattern may be the first sewing pattern 153, and either pattern may be the second sewing pattern 155.

The sewing pattern shown in FIG. 5 (a) includes a first sewing pattern 153 formed as a continuous sewing line 153x having an orientation region A by being formed in a zigzag shape, and the first sewing pattern 153. This is a sewing pattern comprising a second sewing pattern 155 as one continuous sewing line 155y intersecting the sewing line 153x. Although the second sewing pattern 155 is formed of one continuous sewing line 155y as in the case of the first sewing pattern 153, the second sewing pattern 155 has an orientation region A by being formed in a zigzag manner. That is, the sewing pattern shown in FIG. 5 (a) is formed of a first sewing pattern 153 shown in FIG. 5 (b) and a second sewing pattern 155 shown in FIG. 5 (c).
In the sewing pattern of FIG. 5A, either pattern may be the first sewing pattern 153 and any pattern may be the second sewing pattern 155.
Furthermore, the end point _{P 153} of the first sewing pattern 153 shown in FIG. 5 (b), when continuous sewing so as to connect the end point _{P 155} of the second sewing pattern 155 shown in FIG. 5 (c), a is the One sewing pattern 153 and the second sewing pattern 155 are formed by one continuous sewing line. That is, the sewing pattern of the interior component base material 11 can be formed by a single sewing line.

The sewing pattern shown in FIG. 6 includes a first sewing pattern 153 formed as an aggregate of a plurality of sewing lines 153x that are concentrically oriented (concentrically arranged), and a sewing line 153x that constitutes the first sewing pattern 153. And a second sewing pattern 155 formed by an assembly of sewing lines 155y intersecting with each other.
Unlike the second sewing pattern 155 constituting the sewing pattern of FIGS. 3 to 5, the second sewing pattern 155 constituting the sewing pattern of FIG. 6 is not oriented. However, since the first sewing pattern 153 is oriented (that is, has an orientation region), the intersection points with the first sewing pattern 153 are well dispersed on the sewing pattern.

The sewing pattern of the interior part base material 11 can have other sewing patterns in addition to the two sewing patterns of the first sewing pattern 153 and the second sewing pattern 155 described above. Other sewing patterns may include only one or a plurality of sewing patterns. By providing more different groups of sewing lines, more intersection points can be obtained.
For example, the sewing pattern shown in FIG. 7 is an example including another sewing pattern. That is, the sewing pattern has three types of sewing line groups, that is, a first sewing pattern 153, a second sewing pattern 155, and a third sewing pattern 157. More specifically, the first sewing pattern 153 is formed as an assembly of a plurality of sewing lines 153x that are vertically oriented (arranged in parallel to the longitudinal direction), and obliquely oriented (inclined and parallel to the sewing lines 153x). A plurality of second sewing patterns 155 formed as an assembly of a plurality of arranged sewing lines 155y, and a plurality of slanted orientations (inclined with respect to the sewing lines 153x and arranged in parallel with an inclination opposite to 155y). And a third sewing pattern 157 formed as an aggregate of the sewed sewing line 157z.
The first sewing pattern 153, the second sewing pattern 155, and the third sewing pattern 157 intersect each other. That is, the first sewing pattern 153 intersects with the second sewing pattern 155 and the third sewing pattern 157, the second sewing pattern 155 intersects with the first sewing pattern 153 and the third sewing pattern 157, and the third sewing pattern. 157 intersects the first sewing pattern 153 and the second sewing pattern 155. Therefore, in the sewing pattern of FIG. 7, which pattern may be the first sewing pattern 153, which pattern may be the second sewing pattern 155, and which pattern may be the third sewing pattern 157.

In each sewing line, the sewing pitch is not limited, but may be 1 mm or more and 30 mm or less. The sewing pitch is particularly preferably 2 mm or more and 20 mm or less, more preferably 3 mm or more and 10 mm or less, and particularly preferably 3.5 mm or more and 9 mm or less. Depending on the size of the sewing pitch, the mechanical strength characteristics obtained can be changed as desired.
As for the sewing pitch, 20 adjacent two needle holes are randomly selected from the needle holes 14 arranged on one sewing line, and the distance between the centers of the two adjacent needle holes is selected. It is assumed that the average value of the distances between the 20 centers obtained is measured.
Furthermore, when orienting the sewing lines, the interval (line interval) between the sewing lines is not particularly limited, but can be 5 mm or more and 100 mm or less. The line interval is particularly preferably 6 mm or greater and 70 mm or less, more preferably 7 mm or greater and 40 mm or less, and particularly preferably 8 mm or greater and 30 mm or less. Depending on the size of the line spacing, the characteristics of the obtained mechanical strength can be changed as desired.
In addition, the line interval is 10 points randomly selected from two adjacent sewing lines while maintaining a substantially uniform width, the line interval is measured, and the average of the obtained line intervals is 10 points. It is assumed to be a value. In the case where two or more sewing lines are oriented with a substantially uniform width, each line interval between two adjacent sewing lines is calculated as a first average, and this first The average value between the averages (second average) is defined as the line interval of the entire sewing pattern.

  As described above, the base layer 13 of the interior component base material 11 is formed in the form of the fiber reinforced board 13t including the reinforcing fiber 131 and the first thermoplastic resin 133 or the reinforcing fiber 131 and the first layer in the manufacturing process. 1 It goes through a form such as a form of a mixed fiber mat 13s with resin fibers 133 ′ made of a thermoplastic resin. In these forms, the springback action of the reinforcing fibers 131 can be obtained at the time of final shaping (shaping step). That is, the restraint to the reinforcing fiber 131 by the first thermoplastic resin 133 solidified in the precursor such as preboard is loosened, and can be made thicker as a whole than the original thickness of the preboard. At this time, regions having different thicknesses can be formed as desired. In the base layer 13 obtained in this way, when the portion having a small thickness is compared with the portion having a large thickness, the density of the portion having a large thickness is smaller than that of the portion having a small thickness. That is, a portion having a large thickness has a low density and is an area that can be easily sewn. Therefore, if necessary, by forming the portion (region) where the sewing pattern is to be applied to be thicker and lower density than the other portions, it is possible to pre-form a low density region and a low density line that are easy to sew.

The shape, size, thickness and other dimensions of the interior part base material 11 are not particularly limited, and the use thereof is not particularly limited. Further, the interior part base material 11 and the manufacturing method thereof are widely used as a base material used for interior parts in various fields such as vehicles (automobiles, railway vehicles, etc.), aircraft, ships, architecture, and the like, and a manufacturing method thereof. .
Specifically, base materials for vehicle interior parts include base materials for trim parts such as automobile door trims, armrests, upper trims, decorative panels, ornament panels, lower trims, pockets (door trim pockets), and quarter trims; Pillar garnish; cowl side garnish (cowl side trim); base material for seat parts such as side airbag peripheral parts; instrument panel parts such as center cluster, register, center box (door), grab door, airbag peripheral parts Base console base material; overhead console base material; sun visor base material; deck board (luggage board), under tray and other base materials; package tray base material; CRS cover base material; Garnish base; Assis Base of the grip; substrate passing light lever, and the like.
Moreover, as a base material for interior parts for construction, a base material of a door member, a base material of various furniture (desk, chair, shelf, bag, etc.), a base material of a container (tray, etc.), a base material of a protective member Moreover, the base material of a partition member, etc. are mentioned.

[2] Interior component The interior component (1) of the present invention is laminated on the base (11) for the interior component and the one surface (11a) side and / or the facing (11b) side of the interior component substrate (11). An outer skin layer (12).
The skin layer 12 is a layer laminated on the one surface 11a side and / or the facing surface 11b side of the interior component base material 11, and the outer surface thereof becomes the design surface 12a of the interior component 1 (FIGS. 11 and 12). reference). That is, the skin layer 12 is usually a layer that provides the design surface of the interior part 1. When the interior component base material 11 has an uneven shape, the interior component base material 11 is laminated on the surface of the interior component base material 11 following the uneven shape.

The configuration of the skin layer 12 is not particularly limited, and may be composed of only one layer or may be composed of two or more layers. When it consists of two or more layers, for example, a laminate comprising a surface layer having a design surface 12a (for example, synthetic leather or woven fabric) and a cushion layer (arranged on the non-design surface side of the skin layer 12). The skin layer 12 can be obtained. The cushion layer is a layer having elasticity. By having the cushion layer, a feeling of elasticity can be given to the tactile sensation from the design surface 12 a side of the skin layer 12. Although the material which comprises a cushion layer is not limited, For example, a flexible polyurethane foam can be used. In addition, as long as it has sufficient cushioning properties, other soft resin foams, nonwoven fabric sheets, and the like can be used. In addition, if necessary, a nonwoven fabric layer, an air blocking layer or the like can be provided.
In addition to the above surface layer and cushion layer, other layers can be provided. As the other layer, various bonding layers for bonding layers such as the surface layer and the cushion layer can be interposed. Examples of the bonding layer include an adhesive and a thermoplastic resin layer for bonding. Moreover, the ventilation suppression layer etc. which suppress ventilation | gas_flowing to the lamination direction of the interior component 1 are illustrated. These layers may use only one layer or may use two or more layers in combination.

The dimensions, such as the shape, size, and thickness, of the interior part 1 are not particularly limited, and the use is not particularly limited. Further, the interior part 1 and the manufacturing method thereof are widely used as interior parts and manufacturing methods thereof in various fields such as vehicles (automobiles, railway vehicles, etc.), aircrafts, ships, and architectures.
Specifically, automotive interior trims include automotive door trims, armrests, upper trims, decorative panels, ornament panels, lower trims, pockets (door trim pockets), quarter trims, and other trim parts; pillar garnishes; cowl side garnishes (Cowl side trim); Seat system parts such as side airbag peripheral parts; Center cluster, register, center box (door), glove door, instrument panel system parts such as airbag peripheral parts; Center console; Overhead console; Sun visor A deck board (luggage board), an under tray, a package tray, a CRS cover, a seat side garnish, an assist grip, a passing light lever, and the like.
Examples of the interior parts for construction include door members, various furniture (desks, chairs, shelves, bags, etc.), containers (tray, etc.), protective members, partition members, and the like.

[3] Manufacturing Method of Interior Component Base Material <1> First Manufacturing Method The manufacturing method (first manufacturing method) of the interior component base material (11) (see FIG. 13) of the present invention is a reinforcing fiber (131). And a sewing step (PRX) for forming the first sewing pattern (153) and the second sewing pattern (155) on the fiber reinforced board (13t) compressed including the first thermoplastic resin (133),
A shaping step (PR4) for shaping the fiber reinforced board (13t) on which the first sewing pattern (153) and the second sewing pattern (155) are formed.

The sewing step (PRX) is a step of forming the first sewing pattern 153 and the second sewing pattern 155 by sewing the sewing thread 15 on the shaped fiber reinforced board 13t.
This step can be performed using a conventionally known method. That is, various sewing machines and the like can be used as necessary. Further, the sewing may be performed by directly sewing the sewing thread 15 to the fiber reinforced board 13t, or may be performed after a preliminary hole to be the needle hole 14 is provided in the fiber reinforced board 13t in advance.
Further, in the first method, sewing is performed by passing the sewing needle between one surface and the opposite surface of the fiber reinforced board 13t so that the sewing needle penetrates the fiber reinforced board 13t. Although it penetrates between one side and the opposite side of fiber reinforced board 13t, it does not ask whether one sewing thread 15 is penetrated independently. That is, as described above, when the upper thread 15a and the lower thread 15b are used, the upper thread 15a is not required to penetrate the fiber reinforcing board 13t, and similarly, the lower thread 15b is also independent. It is not necessary to penetrate through the fiber reinforced board 13t.
The fiber reinforced board 13t is normally a plate-like body (flat plate shape) that is compressed including the reinforcing fibers 131 and the first thermoplastic resin 133. Although the thickness is not limited, For example, it is 1 mm or more and 10 mm or less.

The shaping step (PR4) is a step of shaping the fiber reinforced board 13t. Usually, the fiber reinforced board 13t on which the first sewing pattern 153 and the second sewing pattern 155 are formed is heated to soften the first thermoplastic resin 133 in the fiber reinforced board 13t and soften the first thermoplastic resin 133. The fiber reinforced board 13t in the finished state is shaped.
Heating may be performed in any way, but it is preferable to perform heating while applying pressure so that compression (restraint of the reinforcing fibers 131 by the first thermoplastic resin 133) is not excessively released by this heating. From such a viewpoint, it is preferable to heat using a hot press machine. The heating conditions and the like can be appropriately set depending on the constituent materials. Specifically, for example, when the first thermoplastic resin 133 contained is a polyolefin, it is preferable to heat to 70 ° C. or higher (temperature inside the fiber reinforced board 13t). The heating temperature is preferably 80 ° C. or higher and 150 ° C. or lower, more preferably 85 ° C. or higher and 130 ° C. or lower, and particularly preferably 90 ° C. or higher and 120 ° C. or lower.
In addition, the shaping can be performed using, for example, a cold press machine. The shaping thickness can be controlled by changing the cavity clearance. That is, in the region where the clearance is large, the constraint on the reinforcing fiber by the first thermoplastic resin 133 is released more, so that it is compressed and released and can be formed thick.
Although the molding conditions at the time of cold press molding are not particularly limited, for example, the mold temperature at the time of molding can be 20 ° C. or more and 60 ° C. or less. The mold clamping time can be 30 seconds or more and 60 seconds or less.

  Moreover, in this 1st manufacturing method, when the sewing thread | yarn 15 contains a 2nd thermoplastic resin, the 2nd thermoplastic resin heating melting process which heat-melts a 2nd thermoplastic resin can be provided. This heating can be performed simultaneously with the heating in the above-mentioned shaping step (PR4) or can be performed separately.

<2> Second Manufacturing Method The manufacturing method (second manufacturing method) of the interior part base material (11) (see FIG. 14) of the present invention includes reinforcing fibers (131) and resin fibers made of a first thermoplastic resin ( 133 ′) and a sewing step (PRX) for forming the first sewing pattern (153) and the second sewing pattern (155) on the mixed fiber mat (13s);
A compression step (PR3) for compressing the mixed fiber mat (13s) on which the first sewing pattern (153) and the second sewing pattern (155) are formed to obtain a fiber reinforced board (13t);
A shaping step (PR4) for shaping the fiber reinforced board (13t).

  The mixed fiber mat 13s is a mat-like material including reinforcing fibers 131 and resin fibers 133 'made of the first thermoplastic resin. It is obtained by the mixed fiber mat forming step PR1. The mixed fiber mat 13s may be obtained in any way. For example, after mixing the resin fiber 133 ′ obtained by fiberizing the first thermoplastic resin 133 and the reinforcing fiber 131 (mixing the fibers). It can be obtained by molding into a mat shape. Various processing can be further performed as necessary. Specifically, fibers can be entangled more highly by needling a laminated mixed fiber layer (laminated web) obtained by laminating a plurality of mixed fiber layers (webs). Further, the laminated fiber layer can be compressed in a non-heated state.

The sewing step (PRX) is a step of forming the first sewing pattern 153 and the second sewing pattern 155 by sewing the sewing thread 15 on the mixed fiber mat 13s.
This step can be performed using a conventionally known method. That is, various sewing machines and the like can be used as necessary.
Further, in the second method, sewing is performed by passing the sewing needle between one surface and the opposite surface of the mixed fiber mat 13s so that the sewing needle penetrates the mixed fiber mat 13s. Although it penetrates between one side and the opposite side of mixed fiber mat 13s, it does not ask whether one sewing thread 15 is penetrated independently. That is, as described above, when the upper thread 15a and the lower thread 15b are used, the upper thread 15a does not need to penetrate the mixed fiber mat 13s, and similarly, the lower thread 15b also alone. It is not necessary to penetrate through the mixed fiber mat 13s.

The compression step (PR3) is a step in which the fiber reinforced board 13t is obtained by compressing the mixed fiber mat 13s on which the first sewing pattern 153 and the second sewing pattern 155 are formed. This step may be performed in any way, and it is sufficient that the fiber reinforced board 13t is obtained. For example, a part or all of the first thermoplastic resin fiber 133 ′ is compressed in a softened or melted state. Thus, the fiber reinforced board 13t can be obtained.
The shaping step PR4 in the first manufacturing method described above can be applied as it is to the shaping step (PR4).

<3> Third Production Method A production method (third production method) for the interior part base material (11) (see FIG. 15) of the present invention comprises a reinforcing fiber (131) and a resin fiber made of a first thermoplastic resin ( 133 ′) and a sewing step (PRX) for forming the first sewing pattern (153) and the second sewing pattern (155) on the mixed fiber mat (13s);
A reinforcing fiber (131) and a resin made of a first thermoplastic resin are provided on one side and / or on the opposite side of the mixed fiber mat (13s) on which the first sewing pattern (153) and the second sewing pattern (155) are formed. An additional laminating step (PR2) of additionally laminating a mixed fiber layer (135) containing fibers (133 ′);
A compression step (PR3) of compressing the mixed fiber mat (13s) additionally laminated with the mixed fiber layer (135) to obtain a fiber reinforced board (13t);
A shaping step (PR4) for shaping the fiber reinforced board (13t).

As the mixed fiber mat 13s to be sewn, the mixed fiber mat 13s in the second manufacturing method described above can be applied as it is. Also, the sewing process PRX in the second manufacturing method described above can be applied as it is to the sewing process (PRX).
In the additional lamination step (PR2), the mixed fiber layer 135 is added to one side of the mixed fiber mat 13s (to be the base layer 134) on which the first sewing pattern 153 and the second sewing pattern 155 are formed and / or the opposite side thereof. It is a process of laminating. The mixed fiber layer 135 is a layer including reinforcing fibers 131 and resin fibers 133 ′ made of the first thermoplastic resin. Specifically, for example, a web used when manufacturing the mixed fiber mat 13s can be used. Moreover, various processes can be further performed as needed. Specifically, needling can be applied to the mixed fiber mat 13s obtained by additionally laminating a mixed fiber layer. Thereby, the base layer 134 and the mixed fiber layer 135 (additional layer) can be firmly entangled. Further, if necessary, the laminated fiber layer (the whole of the base layer 134 and the fiber mixture layer 135) can be compressed in a non-heated state.
In the third production method, the compression step (PR3) and the shaping step (PR4) can be applied as they are in the second production method.

[4] Manufacturing method of interior component The manufacturing method of the interior component (1) of the present invention may be any of the manufacturing method (the first manufacturing method, the second manufacturing method, and the third manufacturing method) of the interior component base material 11. After the shaping step (PR4) in), a skin layer laminating step (PR5) for laminating the skin layer (12s) on one side and / or the opposite side of the shaped fiber reinforced board (13t) is provided (see FIG. 16). ).

That is, the manufacturing method of the interior component 1 is different from the manufacturing method of the interior component base material 11 described above in that a skin layer lamination step PR5 is provided. This skin layer lamination step PR5 is a step of obtaining the interior component 1 by laminating the skin layer 12s on the one surface 11a side and / or the facing surface 11b side of the obtained interior component base material 11. The skin layer 12s laminated in the skin layer lamination step PR5 is a precursor (precursor skin layer) that becomes the skin layer 12 of the interior part 1.
As shown in FIG. 16, in the skin layer stacking process PR5, the base material 11 for interior parts is set on the suction table 53, and while being suctioned from the one surface 11a or the facing surface 11b side of the base material 11 for interior parts, the precursor skin By adsorbing and heating the layer 12s on the other surface (if the suction surface is one surface 11a, the other surface is the facing surface 11b, and if the suction surface is the facing surface 11b, the other surface is the one surface 11a) Can be laminated (joined). The interior component base material 11 is porous because the reinforcing fiber 131 is bound by the first thermoplastic resin 133. Accordingly, suction as described above is possible.
At the time of joining, when each of the interior component base material 11 and the precursor skin layer 12s includes a thermoplastic resin, the thermoplastic resin is softened and melted to laminate the two using the thermoplastic resins. At the same time, they can be joined. In addition to the thermoplastic resin, an adhesive can be used alone or in combination.

Hereinafter, the present invention will be described specifically by way of examples.
[1] Preparation of interior component base material (1) Interior component base material of Example 1 Thickness obtained by compressing after reinforcing fibers and thermoplastic resin fibers were mixed at a mass ratio of 50:50 A fiber reinforcing board 13t having a thickness of 2 mm was prepared {the reinforcing fiber is a kenaf fiber having an average fiber length of 70 mm, and the thermoplastic resin fiber is polypropylene (non-modified: modified = 95 mass%: 5 mass% mixed resin). Spun synthetic fiber (6 dtex, average fiber length 51 mm)}.

By using a polyester yarn having a fineness of 1180 dtex (5th yarn) as the upper yarn 15a, a polyester yarn having a fineness of 740 dtex (8th yarn) as the lower yarn 15b, and sewing on the fiber reinforced board 13t using a 24th sewing needle. The first sewing pattern 153 and the second sewing pattern 155 were provided, and the lattice-shaped sewing pattern shown in FIG. 3A was formed (sewing step PRX), whereby the interior part base material of Example 1 was obtained.
The sewing pitch of the sewing line 153x forming the first sewing pattern 153 was 4.3 mm. Similarly, the sewing pitch of the sewing line 155y forming the second sewing pattern 155 is also set to 4.3 mm. Further, the sewing lines 153x are arranged in parallel at intervals of 20 mm, and the sewing lines 155y are arranged in parallel at intervals of 20 mm. That is, it is as follows.

Next, the fiber reinforced board 13t provided with the first sewing pattern 153 and the second sewing pattern 155 was sandwiched between hot press machines (hydraulic press apparatus equipped with a heater) and heated to a temperature of 210 ° C. After obtaining the fiber reinforced board 13t, the heated fiber reinforced board 13t is supplied to a cold press machine and molded at 20 to 60 ° C. for 30 to 60 seconds (flat plate molding, see FIG. 12). A flat base layer 13 having a thickness of 0.6 mm (a density of 0.65 g / cm ³ ) was obtained (shaping step PR4).

(2) Base material for interior parts of Example 2 A base material for interior parts of Example 2 was obtained in the same manner as Example 1 except that the following configuration was changed.
Sewing pitch of sewing line 153x: 6.0 mm
Sewing pitch of the sewing line 155y: 6.0 mm

(3) Base material for interior parts of Example 3 A base material for interior parts of Example 3 was obtained in the same manner as Example 1 except that the following configuration was changed.
Material of the upper thread 15a: polyparaphenylene benzobisoxazole Material of the lower thread 15b: polyparaphenylene benzobisoxazole The sewing thread 15 using the above polyparaphenylene benzobisoxazole is a trade name “Zylon”.

(4) Base material for interior parts of Example 4 A base material for interior parts of Example 4 was obtained in the same manner as Example 1 except that the following configuration was changed.
Material of upper thread 15a: polyparaphenylene benzobisoxazole Material of lower thread 15b: polyparaphenylene benzobisoxazole Sewing pitch of sewing line 153x: 6.0 mm
Sewing pitch of the sewing line 155y: 6.0 mm
The sewing thread 15 using the polyparaphenylene benzobisoxazole is a trade name “Zylon”.

(5) Base material for interior parts of comparative example A base material for interior parts obtained in the same manner as in Example 1 except that no sewing pattern was provided was used as a comparative example product.

From each of the obtained base materials for interior parts, a 150 mm × 50 mm rectangle was cut out so that each sewing line was substantially perpendicular to the cut surface of the test piece, and test pieces of Examples 1 to 4 and Comparative Example Got.
Next, the flexural modulus was measured according to JIS K7171. In this measurement, while supporting the test piece at two fulcrums (curvature radius 5.0 mm) with a distance between the fulcrums of 100 mm, the working point (curvature radius 3.2 mm) arranged at the center between the fulcrums was changed to a speed of 50 mm / min. The load was applied and the measurement was performed. The results are shown in Table 1.

  From the results in Table 1, it can be seen that excellent mechanical strength can be imparted by providing a sewing pattern to the base layer 13. It can be seen that the mechanical strength can be reinforced by the sewing pattern separately from these configuration changes without changing the configuration of the current interior component base material that is balanced so that each characteristic is skillfully expressed. Moreover, the flexural modulus of the base material for interior parts of Examples 1 to 4 is improved to 1.27 to 2.41 times that of Comparative Example 1. In particular, in Examples 3 to 4 using a high-strength sewing thread, the bending elastic modulus is 1.96 to 2.41 times that of Comparative Example 1, and an extremely remarkable improvement is recognized.

  The foregoing examples are for illustrative purposes only and are not to be construed as limiting the invention. Although the invention has been described with reference to exemplary embodiments, it is to be understood that the language used in the description and illustration of the invention is illustrative and exemplary rather than limiting. As detailed herein, changes may be made in its form within the scope of the appended claims without departing from the scope or spirit of the invention. Although specific structures, materials and examples have been referred to in the detailed description of the invention herein, it is not intended to limit the invention to the disclosure herein, but rather, the invention is claimed. It covers all functionally equivalent structures, methods and uses within the scope.

1; interior parts
11: Base material for interior parts, 11a: One side of base material for interior parts, 11b: One side of base material for interior parts,
12; skin layer, 12a; design surface of skin layer, 12s; precursor skin layer,
13; base layer, 13a; one side of the base layer, 13b; opposite side of the base layer,
131; reinforcing fiber, 133; first thermoplastic resin, 134; base layer (non-additional layer), 135; mixed fiber layer (additional layer),
13s; mixed fiber mat, 13t; fiber reinforced board,
14; needle hole,
15; Sewing thread, 15a; Upper thread, 15b; Lower thread,
151; Sewing pattern (pattern including both first and second sewing patterns)
153; first sewing pattern, 153x; sewing line,
155; second sewing pattern, 155y; sewing line,
157; third sewing pattern, 157z; sewing line,
53; suction table,
A: oriented region, B: non-oriented region,
P ₁₅₃ ; end point, P ₁₅₅ ; end point,
PR1: mixed fiber mat forming step,
PR2; additional lamination process,
PR3; compression process,
PR4; shaping process,
PRX; sewing process,
PR5: skin layer lamination step.

Claims (10)

A base layer including a reinforcing fiber and a first thermoplastic resin binding the reinforcing fibers;
Having one surface of the base layer and a sewing thread that is sewn through the opposite surface;
The sewing thread forms a first sewing pattern and a second sewing pattern,
The first sewing pattern has a plurality of sewing patterns oriented in a predetermined direction,
The second sewing pattern has a plurality of sewing patterns intersecting the first sewing pattern,
The base material for interior parts, wherein the needle hole through which the sewing thread is inserted is closed by a melted and solidified first thermoplastic resin. A base layer including a reinforcing fiber and a first thermoplastic resin binding the reinforcing fibers;
A sewing thread sewn inside the base layer without penetrating through at least one of the one surface and the opposite surface of the base layer;
The sewing thread forms a first sewing pattern and a second sewing pattern,
The first sewing pattern has a plurality of sewing patterns oriented in a predetermined direction,
The second sewing pattern has a plurality of sewing patterns intersecting the first sewing pattern,
The base material for interior parts, wherein the needle hole through which the sewing thread is inserted is closed by a melted and solidified first thermoplastic resin.   The base material for interior parts according to claim 1 or 2, wherein the fineness of the sewing thread is 500 dtex or more and 1300 dtex or less. The sewing thread includes a second thermoplastic resin,
The interior part base material according to any one of claims 1 to 3, wherein the second thermoplastic resin is melted and solidified in the needle hole. A base material for interior parts according to any one of claims 1 to 4,
An interior component comprising: a skin layer laminated on one side and / or the opposite side of the interior component base material. It is a manufacturing method of the substrate for interior parts according to claim 1,
A sewing step of forming the first sewing pattern and the second sewing pattern on a fiber reinforced board compressed including the reinforcing fiber and the first thermoplastic resin;
And a shaping step of shaping the fiber reinforced board on which the first sewing pattern and the second sewing pattern are formed. It is a manufacturing method of the substrate for interior parts according to claim 1,
A sewing step of forming the first sewing pattern and the second sewing pattern on a mixed mat of the reinforcing fibers and the resin fibers made of the first thermoplastic resin;
A compression step of obtaining a fiber reinforced board by compressing the mixed fiber mat formed with the first sewing pattern and the second sewing pattern;
And a shaping step of shaping the fiber reinforced board. It is a manufacturing method of the substrate for interior parts according to claim 2,
A sewing step of forming the first sewing pattern and the second sewing pattern on a mixed mat of the reinforcing fibers and the resin fibers made of the first thermoplastic resin;
A mixed fiber layer including the reinforcing fiber and the resin fiber made of the first thermoplastic resin is provided on one side and / or the opposite side of the mixed fiber mat on which the first sewing pattern and the second sewing pattern are formed. An additional layering process for additional layering;
A compression step of obtaining a fiber reinforced board by compressing a mixed fiber mat additionally laminated with the mixed fiber layer;
And a shaping step of shaping the fiber reinforced board. When the sewing thread contains the second thermoplastic resin,
The manufacturing method of the base material for interior components in any one of Claims 6 thru | or 8 provided with the 2nd thermoplastic resin heating-melting process of heat-melting a said 2nd thermoplastic resin. It is a manufacturing method of the interior component according to claim 5,
After the shaping step in the method for producing a base material for interior parts according to any one of claims 6 to 8,
A method for producing an interior part, comprising a skin layer laminating step of laminating a skin layer on one side and / or the opposite side of a shaped fiber reinforced board.

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