JP2019136987A - Fiber-containing resin molding - Google Patents

Abstract

To improve the durability of a hinge part in a fiber-containing resin molding.SOLUTION: A fiber-containing resin molding 10 has a hinge part 15 that can be bent and deformed, the fiber-containing resin molding 10 having a thermoplastic resin, a vegetable fiber and a high-strength fiber.SELECTED DRAWING: Figure 3

Description

  The technology disclosed in this specification relates to a fiber-containing resin molded body.

  Conventionally, fiber-containing resin moldings obtained by heating and pressing a mixture of plant fibers and thermoplastic resins (fibers) are door trim base materials, inner panels, pillar garnishes, rear packages, ceiling base materials, shock absorbers, sound absorbing materials. Interior materials for vehicles such as materials; Building materials such as wall materials, floor materials, under-floor impact absorbing materials, and heat insulating materials: widely used as equipment materials such as speaker boxes and sound absorbing materials (for example, Patent Document 1) reference).

JP 2001-179716 A

  When the fiber-containing resin molded body as disclosed in Patent Document 1 is provided with a hinge part that can be bent and deformed, the hinge part may be cracked by repeatedly bending and deforming the hinge part.

  The technology disclosed in this specification has been completed based on the above-described circumstances, and an object thereof is to improve the durability of the hinge portion in the fiber-containing resin molded body.

  In order to solve the above problems, a fiber-containing resin molded body disclosed in the present specification is a fiber-containing resin molded body having a hinge part that can be bent and deformed, and includes a thermoplastic resin, a vegetable fiber, and a high-strength fiber. To do.

  According to such a fiber-containing resin molded body, when the hinge portion is bent and deformed, a part of the load acting on the hinge portion can be released as friction energy between the high strength fiber and the thermoplastic resin. The durability of the hinge part can be improved.

  In the fiber-containing resin molded body, a surface of the hinge portion may be covered with a skin material. According to the fiber-containing resin molded body containing high-strength fibers, the durability of the hinge part is improved, so that the skin material is difficult to tear due to cracking of the hinge part, etc., and the fiber-containing resin molded body is covered with the skin material. The design of the broken parts can be improved.

  In the fiber-containing resin molded body, the skin material may be bonded to the surface of the hinge portion with the thermoplastic resin. In such a configuration, for example, the force from the fiber-containing resin molded body is directly compared to a structure having an intervening layer such as an adhesive layer separate from the thermoplastic resin between the fiber-containing resin molded body and the skin material. In particular, it acts on the skin material, resulting in a structure in which the skin material is easy to tear due to cracks in the hinge portion or the like. On the other hand, according to the fiber-containing resin molded body containing high-strength fibers, even if the skin material is bonded to the surface of the hinge portion by the thermoplastic resin by improving the durability of the hinge portion, the skin material It becomes possible to suppress tearing of the film. As a result, the intervening layer interposed between the fiber-containing resin molded body and the skin material can be eliminated, and the product value of the fiber-containing resin molded body can be improved.

  In the fiber-containing resin molded body, the high-strength fiber may have a tensile modulus of 27 GPa or more.

  In the fiber-containing resin molded body, the high-strength fiber may be at least one selected from an aramid fiber, a polyparaphenylene benzobisoxazole fiber, a carbon fiber, and a glass fiber.

  In the said fiber containing resin molding, even if the content rate of the said plant fiber and the said high strength fiber is 20-95 mass% and 1-40 mass% with respect to the whole said fiber containing resin molding, respectively. Good.

  In the fiber-containing resin molded body, the thermoplastic resin may be an olefin resin.

  According to the technique disclosed in this specification, the durability of the hinge portion in the fiber-containing resin molded body can be improved.

The perspective view which shows the luggage board which concerns on one Embodiment Top view of the luggage board (A) A cross-sectional view showing a state where the hinge part is not bent and deformed, cut along line III-III in FIG. 2, (B) a state where the hinge part is bent and deformed, and the second board part is bent upward. (C) Cross-sectional view showing a state in which the hinge part is bent and deformed, and the second board part is bent downward Explanatory drawing explaining a fiber mat formation process Explanatory drawing explaining the molding process Table showing tensile elastic modulus, tensile breaking elongation, Charpy impact strength, and impact resistance of fiber base materials in Comparative Examples and Examples Table showing durability of hinge part of fiber base material in comparative examples and examples Explanatory drawing explaining the formation process which concerns on other embodiment. Sectional view of a conventional luggage board

  One embodiment will be described with reference to FIGS. In this embodiment, the fiber base material 10 which comprises the luggage board 110 is illustrated as a fiber containing resin molding. The luggage board 110 is installed in, for example, the luggage compartment 100 provided at the rear of the vehicle.

  As shown in FIG. 1, the luggage compartment 100 has a shape in which the width corresponding to the wheel base of the vehicle protrudes toward the indoor side, thereby reducing the width of the front portion and increasing the width of the rear portion. . A luggage compartment opening 100A is formed on the rear upper side of the luggage compartment 100, and a back door (not shown) for closing the cargo compartment opening 100A is provided. The luggage compartment 100 has a rear dimension in the vehicle width direction that is larger than the width dimension of the luggage compartment opening 100A.

  As shown in FIG. 1, the luggage board 110 is disposed so as to close the storage chamber 100 </ b> B that is recessed in the floor of the cargo chamber 100. Specifically, the luggage board 110 has a configuration in which a peripheral end portion thereof is placed on a placement surface formed on the periphery of the storage chamber 100B. With such a configuration, in addition to being able to shield luggage (for example, spare tires and tools) accommodated in the storage room 100B with the luggage board 110, it is also possible to place the luggage on the luggage board 110.

  As shown in FIG. 3, the luggage board 110 covers the fiber base material 10, the first skin material 111 (an example of the skin material) that covers the upper surface 10 </ b> A of the fiber base material 10, and the lower surface 10 </ b> B of the fiber base material 10. And a second skin material 112 (another example of the skin material). The first skin material 111 constitutes the design surface of the luggage board 110, and the second skin material 112 constitutes the back surface (the surface on the storage chamber 100B side) of the luggage board 110. In this embodiment, the 1st skin material 111 and the 2nd skin material 112 illustrate what comprises a nonwoven fabric etc. which consist of a general purpose polyethylene terephthalate fiber, for example.

  As shown in FIG. 2, the fiber base material 10 includes a hinge portion 15 that can be bent and deformed. Specifically, the fiber base 10 includes a first board portion 16 having a substantially rectangular shape in plan view, second board portions 17 and 17 projecting from the first board portion 16 to both sides in the vehicle width direction, and a second board. Formed on the projecting base end portion of the portion 17, it has hinge portions 15, 15 for rotating the second board portions 17, 17 with respect to the first board portion 16. The luggage board 110 is configured such that the entire width can be reduced by bending the fiber base material 10 at the hinge portion 15. With such a configuration, the luggage board 110 can be easily laid on the floor of the luggage compartment 100 from the luggage compartment opening 100A, and the luggage board 110 can be easily displaced in the luggage compartment 100 to open and close the storage compartment 100B. . A hinge portion 19 having the same configuration as the hinge portion 15 is also provided on the vehicle front side of the first board portion 16.

  As shown in FIG. 3, the hinge portion 15 is an integral hinge and is constituted by a part of the fiber base material 10. The hinge portion 15 is a portion of the fiber base 10 that is thinner than the general portion (the first board portion 16 and the second board portion 17). Specifically, the hinge portion 15 is formed by groove portions 15A and 15B that are recessed in the upper surface 10A and the lower surface 10B of the fiber base material 10, respectively. The groove portions 15A and 15B extend linearly along the protruding base end portion of the second board portion 17, and stress is concentrated on the hinge portion 15 when a force is applied to the second board portion 17 in the bending direction. Thus, the fiber base 10 is easily bent. The hinge portion 15 has the second board portion 17 from the initial state shown in FIG. 3A to the upper surface 10A side to about 150 ° (FIG. 3B; angle α ≦ 150 °) and 85 ° to the lower surface 10B side. It is configured to be bendable to an extent (FIG. 3C; angle β ≦ 85 °).

  As shown in FIG. 3, the first skin material 111 and the second skin material 112 are made of the upper surface 10 </ b> A and the lower surface 10 </ b> B (upper and lower sides of the hinge portion 15) of the fiber base material 10 by the thermoplastic resin contained in the fiber base material 10. Each side surface). Specifically, the first skin material 111 is impregnated with a non-woven fabric constituting the first skin material 111 by a part of the thermoplastic resin derived from the fiber base material 10 when the fiber base material 10 is molded. It is stuck on the upper surface 10A of the fiber base 10 (see FIG. 5). In the present embodiment, the second skin material 112 is also attached to the lower surface 10B of the fiber base material 10 in the same manner. In such a configuration, for example, as in other embodiment (5) described later, compared to a configuration in which the second skin material 112 is adhered to the fiber base material 10 in the process of forming the preboard 13 from the fiber mat 11. Although the peel strength of the second skin material 112 from the fiber base material 10 is small, deterioration in appearance quality such as hair fall is suppressed, and the second skin material 112 follows deformation and cracking of the fiber base material 10. It has a structure that is difficult to tear.

  Then, the material of the fiber base material 10 is demonstrated. The fiber base material 10 is an article containing a thermoplastic resin, a vegetable fiber, and a high strength fiber, and preferably, the plant fibers, the high strength fibers, or these fibers are bonded to the thermoplastic resin, This is a resin molded body in which plant fibers and high-strength fibers are dispersed in a matrix containing a thermoplastic resin.

The thermoplastic resin according to the present invention is not particularly limited, and is an olefin resin such as polypropylene, polyethylene, and ethylene / propylene random copolymer; an aliphatic polyester resin such as polylactic acid, polycaprolactone, and polybutylene succinate; and polyethylene terephthalate. Polyester resin such as aromatic polyester resin such as polytrimethylene terephthalate and polybutylene terephthalate; polystyrene; acrylic resin; polyamide resin; polycarbonate resin; polyacetate resin; The thermoplastic resin may be modified (acid anhydride modification, carboxylic acid modification, epoxy modification, or oxazoline modification) in order to increase the affinity for the surface of plant fibers or high strength fibers.
The thermoplastic resin is preferably an olefin resin and a polyester resin, and more preferably an olefin resin such as polypropylene.

The plant fiber according to the present invention is not particularly limited, and fibers derived from stems, stems, branches, leaves, roots and the like in plants may be included as they are, and these include heat treatment, drying treatment, pulverization treatment, It may be processed by chemical treatment or the like.
The plant fiber is preferably kenaf, jute hemp, manila hemp, sisal hemp, crust, cocoon, cocoon, banana, pineapple, coconut palm, corn, sugar cane, bagasse, palm, papyrus, cocoon, esparto, surabigrass, wheat, rice, It is a linear fibrous body derived from bamboo, conifers (cedar, birch, etc.), hardwoods, cotton and the like. Among these, the mallow is a plant that has a woody stem, is an extremely fast growing annual plant, has an excellent carbon dioxide absorption, contributes to reducing the amount of carbon dioxide in the atmosphere, effective use of forest resources, etc. Particularly preferred is a linear fiber body (kenaf fiber) derived from kenaf. Examples of the kenaf include hibisuc cannabinus and hibisuc sabdariffa in scientific names, and red sesame, cuban kenaf, western hemp, taykenaf, mesta, bimli, ambari and bombay hemp in common names.

  The plant fiber is usually solid, and its length (fiber length) and outer diameter (fiber diameter) are not particularly limited. The upper limit of the fiber length is preferably 150 mm. In addition, the average value of the said fiber length becomes like this. Preferably it is 10-100 mm, More preferably, it is 30-80 mm. The upper limit of the fiber diameter is preferably 1500 μm. The average fiber diameter is preferably 20 to 500 μm, more preferably 20 to 200 μm.

  The shape of the plant fiber contained in the fiber base material 10 is not particularly limited. The shape in the length direction can be a straight line, a broken line, a curved line, a spiral, or a deformed form thereof. The outer shape of the cross section may be a circle, an ellipse, a polygon, or a deformed shape thereof.

The content ratio of the plant fiber contained in the fiber base material 10 is preferably 20 to 95% by mass, more preferably 30 to 70% by mass with respect to the entire fiber base material 10 from the viewpoint of maintaining the structure of the molded body. is there.
Moreover, the content rate of the said vegetable fiber when the sum total of the said vegetable fiber and high strength fiber is 100 mass% becomes like this. Preferably it is 40-98 mass%, More preferably, it is 70-90 mass%.

  The high-strength fiber according to the present invention preferably has a tensile elastic modulus measured according to JIS L 1015 or JIS L 1013, preferably 27 GPa or more, more preferably 40 GPa or more, still more preferably 50 GPa or more, and particularly preferably 60 GPa or more. It is. Examples of the high-strength fibers include aramid fibers (para type or meta type), polyparaphenylene benzobisoxazole fibers (hereinafter referred to as “PBO fibers”), carbon fibers, glass fibers, silicon carbide fibers, PBT fibers, and polyamideimide fibers. , Polyimide fiber, polyarylate fiber, polyazomethine fiber and the like. The high-strength fiber contained in the fiber base material 10 of the present invention may be only one type or two or more types. The high-strength fibers are preferably aramid fibers, PBO fibers, carbon fibers, and glass fibers, and particularly preferably aramid fibers and PBO fibers. In the case of these fibers, from the viewpoint of impact resistance, the thermoplastic resin is preferably a resin having a low affinity with plant fibers, that is, a non-modified resin, and particularly preferably a non-modified olefin resin. It is. For example, when the thermoplastic resin contains a non-modified olefin resin, when the fiber substrate 10 receives an impact, the impact energy is converted into friction energy, while the high-strength fiber receives the remaining impact energy, Since the high-strength fiber to which the plastic resin is sufficiently bonded follows, the fiber substrate 10 is excellent not only in rigidity but also in impact resistance.

  The high-strength fibers are usually solid, and the length (fiber length) and outer diameter (fiber diameter) are not particularly limited. The upper limit of the fiber length is preferably 150 mm. In addition, the average value of the said fiber length becomes like this. Preferably it is 10-100 mm, More preferably, it is 30-80 mm. The upper limit of the fiber diameter is preferably 1000 μm. In addition, the average value of the said fiber diameter becomes like this. Preferably it is 3-500 micrometers, More preferably, it is 3-100 micrometers.

  The high-strength fiber contained in the fiber substrate 10 may be in any form of a fiber-like single fiber, a filament-like fiber bundle, and a tow-like twisted fiber. Moreover, the shape of the said high strength fiber is not specifically limited. The shape in the length direction can be a straight line, a broken line, a curved line, a spiral, or a deformed form thereof. The outer shape of the cross section may be a circle, an ellipse, a polygon, or a deformed shape thereof.

  Although the content rate of the high strength fiber contained in the fiber base material 10 is not specifically limited, From a viewpoint of the mechanical physical property of a molded object, Preferably it is 1-40 mass% with respect to the whole fiber base material 10, More preferably It is 2-20 mass%.

  The fiber base material 10 can further contain other components in addition to the thermoplastic resin, the plant fiber, and the high strength fiber. Examples of other components include additives, balloons, and the like that are conventionally included in known thermoplastic resin molded products.

  The method for producing the fiber substrate 10 is not particularly limited, but a preferred production method is a method in which a fiber mixture of plant fibers and high-strength fibers and a molten thermoplastic resin is conventionally used in a known molding process. is there.

The fiber mixture is, for example, a fiber aggregate obtained by mixing (mixing) thermoplastic resin molded bodies (pellets, fibrous materials, etc.), plant fibers, and high-strength fibers. it can.
The molded body of the thermoplastic resin is preferably a thermoplastic resin fiber, and the shape thereof may be any of a linear shape, a curved shape, a spiral shape, and the like.
The fiber length of the thermoplastic resin fiber is preferably 30 mm or more, more preferably 30 to 100 mm, and still more preferably 30 to 70 mm. When the fiber length is 30 mm or more, sufficient entanglement of the thermoplastic resin fibers, as well as sufficient entanglement of the thermoplastic resin fibers, the plant fibers, and the high-strength fibers can be easily obtained. A fiber-containing resin molded body in which plant fibers and high-strength fibers are uniformly dispersed can be efficiently produced. In addition, although the fiber diameter of the said thermoplastic resin fiber is not specifically limited, Preferably it is 5-100 micrometers, More preferably, it is 20-100 micrometers, More preferably, it is 30-100 micrometers.
The plant fiber and the high strength fiber used for the formation of the fiber assembly are as described above.

The proportions of the thermoplastic resin fibers, plant fibers, and high-strength fibers used in forming the fiber assembly are preferably 4 to 79% by mass and 20%, respectively, when the total of these is 100% by mass. It is -95 mass% and 1-40 mass%, More preferably, it is 10-68 mass%, 30-70 mass%, and 2-20 mass%.
When forming the fiber assembly, an air array method, a card method, or the like can be applied, and thereafter, entanglement or the like may be performed as necessary.

  In the case of a fiber assembly including thermoplastic resin fibers, the thermoplastic resin fibers are heated to a temperature at which the thermoplastic fibers are melted, and the plant fibers and high-strength fibers are not melted. 10 can be manufactured. The heating temperature is appropriately selected depending on the type of resin constituting the thermoplastic resin fiber.

  The fiber base material 10 is excellent in rigidity and impact resistance. With respect to impact resistance, when Charpy impact strength is used as an index, it is preferably 30% or more, more preferably with respect to a molded article not containing high-strength fibers. Exhibits performance of 80% or more, particularly preferably 100% or more. As described above, since the fiber-containing resin molded body of the present invention has a property that is difficult to break, not only a plate body but also a fiber-containing resin molded body of any shape such as one having a convex portion can be applied to a wide range of uses. Can do.

  Then, an example of the manufacturing method of the fiber base material 10 is demonstrated. The manufacturing method of the fiber base material 10 includes a fiber mat forming step of obtaining a fiber mat 11 by blending plant fibers 21, high-strength fibers 23, and thermoplastic resin fibers 31 made of the thermoplastic resin, and fibers. The mat 11 is heated to a temperature that is equal to or higher than the temperature at which the thermoplastic resin fibers 31 melt and the high strength fibers 23 can maintain the fiber state, and a molding process is performed to mold the fiber substrate 10. Each of the plant fiber 21, the high-strength fiber 23, and the thermoplastic resin fiber 31 can be appropriately selected from known or manufactured methods, or commercially available fibers.

  The above “mixed fiber” means that the fiber of the plant fiber 21, the high strength fiber 23, and the thermoplastic resin fiber 31 are mixed to obtain a fiber mixture (for example, a mat-like material). In this case, the fiber mixing method is not particularly limited, and various methods can be used. Usually, a dry method or a wet method is used, and among these, the dry method is preferable. In this embodiment, in order to use the vegetable fiber which has a hygroscopic property, when a wet method (papermaking method etc.) will be used, an advanced drying process will be needed, Therefore The dry method which can be manufactured more simply is preferable. Examples of the dry method include an air array method and a card method, and the fiber mat forming step by the card method will be described below.

  In the fiber mat forming step, as shown in FIG. 4, the plant fiber 21, the high-strength fiber 23, and the thermoplastic resin fiber 31 are mixed at a predetermined blending ratio and are put into the fiber supply unit 41. Each fiber 21, 23, 31 put into the fiber supply unit 41 is continuously supplied from the fiber supply unit 41 to the card machine 43 to be a web. Thereafter, the web is entangled by an entanglement means (needle punch device) 45 and then cut by a cutter 47 to obtain a fiber mat 11. In the technology disclosed in the present specification, a conventional fiber is adopted by adopting a structure including fibrous high-strength fibers 23 as a structure for enhancing durability and impact resistance of the hinge portion 15 of the fiber base 10. The fiber mat 11 can be formed using a card machine 43 or the like used for manufacturing the base material.

  In the molding step, the thermoplastic resin fibers 31 in the fiber mat 11 are melted, and the mixed fibers of the plant fibers 21 and the high strength fibers 23 are bound by the thermoplastic resin 30. When the thermoplastic resin 30 constituting the thermoplastic resin fiber 31 is made of polypropylene, the heating temperature is preferably 170 to 240 ° C, and more preferably 200 to 210 ° C.

  In the molding step, the fiber base material 10 is press-molded by performing compression simultaneously with the above heating (for example, hot press molding method) or after the heating (for example, cold press molding method). By performing the compression, the mixed fibers can be bound to each other with the thermoplastic resin 30 more firmly than in the case where the compression is not performed. Although the pressurization pressure at the time of performing this compression is not specifically limited, it is preferable to set it as 1-10 Mpa, and it is more preferable to set it as 1-5 Mpa. In addition, when this compression is performed, shaping can be performed at the same time. For example, by using a molding device (double belt press machine or dies 54 and 55 described later) for compression, it can be shaped into a plate shape or other various shapes. When the plate is shaped, it can be used as it is, but the final shape can also be obtained by further subjecting the plate-like pre-board 13 to main molding. That is, it is possible to include a pre-forming step for forming the preboard 13 and a main forming step for shaping into a final shape. Hereinafter, the forming process by the cold press forming method will be described.

  In the molding step, the fiber mat 11 is heated and compressed by, for example, a double belt press to obtain a preboard 13. Then, the preboard 13 in a state where the internal thermoplastic resin 30 is melted is disposed between the mold 54 and the mold 55 of the molding apparatus 53. At this time, the first skin material 111 is disposed between one plate surface of the preboard 13 and the mold 54, and the second skin material 112 is disposed between the other plate surface of the preboard 13 and the mold 55. (See FIG. 5). Thereafter, the mold 54 and the mold 55 are closed. The mold 54 and the mold 55 are provided with protrusions (not shown) for forming the groove portions 15A and 15B of the hinge portion 15, and the cavity is narrowed at the portion corresponding to the hinge portion 15 in the fiber base material 10. Yes. When the fiber mat 11 is pressed by the metal mold 54 and the metal mold 55 and the internal thermoplastic resin 30 is cooled and solidified, the fiber substrate 10 provided with the hinge portion 15 is obtained. Further, the first skin material 111 is bonded to the upper surface 10A of the fiber base material 10 and the second skin material 112 is bonded to the lower surface 10B by the thermoplastic resin 30 that has exuded from the fiber base material 10 by the press pressure. . Such a press pressure is larger in the hinge portion 15 than in the general portion (the first board portion 16 and the second board portion 17). For this reason, the adhesive strength of the skin materials 111 and 112 in the hinge portion 15 tends to be higher than the adhesive strength of the skin materials 111 and 112 in the general portion, resulting in stress concentration on the hinge portion 15, This is one of the factors that make 112 easily break.

  Then, the effect | action and effect of this embodiment are demonstrated. According to the fiber base material 10 of the present embodiment, when the hinge portion 15 is bent and deformed, a part of the load acting on the hinge portion 15 is released as friction energy between the high-strength fiber and the thermoplastic resin. The durability of the hinge portion 15 can be improved.

  Furthermore, according to this embodiment, not only has a high rigidity by including plant fibers and high-strength fibers, but also provides a fiber base material 10 that is superior in impact resistance compared to the case of including only plant fibers. Can do.

  In the present embodiment, the surface of the hinge portion 15 is covered with the first skin material 111 and the second skin material 112. According to the fiber base material 10 including high-strength fibers, the durability of the hinge portion 15 is improved, so that the first skin material 111 and the second skin material 112 are not easily torn due to cracking of the hinge portion 15 and the like. The design of the luggage board 110 can be improved.

  In the present embodiment, the first skin material 111 and the second skin material 112 are bonded to the surface of the hinge portion 15 with the thermoplastic resin 30. For this reason, for example, the force from the fiber substrate 10 is directly compared to a structure having an intervening layer such as an adhesive layer different from the thermoplastic resin 30 between the fiber substrate 10 and the first skin material 111. In addition, the first skin material 111 acts on the first skin material 111, and the first skin material 111 is easily torn due to the crack of the hinge portion 15 or the like. In addition, as an intervening layer, the film 2 which consists of thermoplastic resins like the comparative example 1-2 mentioned later can be illustrated (refer FIG. 9). Even if such a film 2 is a case where a crack etc. arise in the hinge part 15, the fiber base material 1 is covered, extending | stretching and deform | transforming, and the fracture | rupture surface etc. of the fiber base material 1 make it difficult to hit the skin materials 111 and 112 Play. On the other hand, according to the fiber base material 10 including high-strength fibers, the durability of the hinge portion 15 is improved, so that the first skin material 111 and the second skin material 112 are placed on the surface of the hinge portion 15 by the thermoplastic resin 30. Even if it is the structure adhered, it becomes possible to suppress the tearing of the first skin material 111 and the second skin material 112. As a result, the intervening layer (film or the like) interposed between the fiber base material 10 and the skin materials 111 and 112 can be eliminated, and the product value of the fiber base material 10 can be improved.

  Moreover, according to the manufacturing method of the fiber base material 10 of this embodiment, for example, in the manufacturing method of the conventional fiber composite material which does not contain a high strength fiber, a high strength fiber is added at a fiber mat formation process, and vegetable fiber and The fiber base material 10 can be manufactured by mixing with thermoplastic resin fibers and appropriately setting the heating temperature in the molding step. For this reason, the fiber base material 10 which was excellent in durability of the hinge part 15 from the product manufactured by the conventional manufacturing method can be obtained with the man-hour and equipment equivalent to the conventional manufacturing method.

  Hereinafter, the embodiment of the present invention will be described more specifically with reference to examples. However, the present invention is not limited to these examples.

[1] Raw material 1-1. Plant fiber A kenaf fiber having an average diameter of 0.05 mm and a fiber length of 70 mm was used.
1-2. High-strength fiber (1) PBO fiber A PBO fiber “Zylon” (trade name) manufactured by Toyobo Co., Ltd. having a fineness of 1.7 dtex and a fiber length of 50 mm was used. The tensile elastic modulus according to JIS L 1013 is 180 GPa.
(2) Aramid fiber X
Para-aramid fiber “Technola” (trade name) manufactured by Teijin Ltd. having a fineness of 1.7 dtex and a fiber length of 50 mm was used. The tensile elastic modulus according to JIS L 1013 is 33 GPa.
(3) Aramid fiber Y
Para-aramid fiber “Toaron” (trade name) manufactured by Teijin Ltd. having a fineness of 1.7 dtex and a fiber length of 50 mm was used. The tensile elastic modulus according to JIS L 1013 is 33 GPa.
1-3. Thermoplastic Resin Fiber (1) Polypropylene Fiber A resin fiber having a fineness of 6.6 dtex and a fiber length of 51 mm obtained by melt spinning a polypropylene resin “NOVATEC SA01” (trade name) manufactured by Nippon Polypro Co., Ltd. was used.
(2) Acid-modified polypropylene fiber Obtained by dry blending 95% by mass of the above polypropylene resin and 5% by mass of maleic anhydride-modified polypropylene resin “Modic P908” (trade name) manufactured by Mitsubishi Chemical Corporation, and then melt spinning. A resin fiber having a fineness of 6.6 dtex and a fiber length of 51 mm was used.

[2] Manufacture and evaluation of fiber substrate (1) Example 1
45 mass parts kenaf fiber, 5 mass parts PBO fiber, and 50 mass parts polypropylene fiber were laminated | stacked with the card machine, and the fiber assembly was produced.
Next, this fiber assembly was heated and compressed (235 ° C., 60 seconds) by a hot plate press to obtain a mat having a thickness of about 3 mm. Thereafter, the mat was subjected to a cooling press for 60 seconds to obtain a plate-shaped resin molded body (board) having a temperature of 25 ° C., a size of 50 mm × 150 mm × 2.5 mm, and a basis weight of 1.5 kg / m ² . .

The obtained board was measured for Charpy impact strength (based on ISO 179-1) and flexural modulus (based on ISO 14125), which were 28.7 kJ / m ² and 2921 MPa, respectively (see FIG. 6). See table). In measuring the flexural modulus, a test piece (length 150 mm, width 50 mm and thickness 4 mm) was used, and the test piece was measured at two fulcrums (curvature radius 5.0 mm) with a distance between fulcrums (L) of 100 mm. While supporting, a load was applied at a speed of 50 mm / min from an action point (curvature radius of 3.2 mm) arranged in the center between the fulcrums.

(2) Example 2
A plate-like resin molded body (board) was obtained in the same manner as in Example 1 except that 48 parts by mass of kenaf fiber, 2 parts by mass of PBO fiber, and 50 parts by mass of polypropylene fiber were used as raw materials. And when the Charpy impact strength and bending elastic modulus were measured about the obtained board, they were 27.4 kJ / m < ² > and 2780 MPa, respectively (refer the table | surface of FIG. 6).

(3) Example 3
A plate-like resin molded body (board) was obtained in the same manner as in Example 1 except that the aramid fiber X was used instead of the PBO fiber. And when the Charpy impact strength and bending elastic modulus were measured about the obtained board, they were 30.5 kJ / m < ² > and 2575 MPa, respectively (refer the table | surface of FIG. 6).

(4) Example 4
Example 1 except that 47.5 parts by mass of polypropylene fiber and 2.5 parts by mass of acid-modified polypropylene fiber were used instead of 50 parts by mass of polypropylene fiber, and aramid fiber Y was used instead of PBO fiber. In the same manner as above, a plate-like resin molded body (board) was obtained. And when the Charpy impact strength and bending elastic modulus were measured about the obtained board, they were 17.6 kJ / m < ² > and 2662 MPa, respectively (refer the table | surface of FIG. 6).

(5) Example 5
A plate-shaped resin molded body (board) was obtained in the same manner as in Example 1 except that the aramid fiber Y was used instead of the PBO fiber. And when the Charpy impact strength and bending elastic modulus were measured about the obtained board, they were 26.6 kJ / m < ² > and 2589 MPa, respectively (refer the table | surface of FIG. 6).

(6) Comparative Example 1
A plate-like resin molded body (board) was obtained in the same manner as in Example 1 except that 50 parts by mass of kenaf fiber and 50 parts by mass of polypropylene fiber were used as raw materials. And when the Charpy impact strength and bending elastic modulus were measured about the obtained board, they were 12.5 kJ / m < ² > and 2290 MPa, respectively (refer the table | surface of FIG. 6).

[3] Manufacture and evaluation of fiber base material provided with hinge part (1) Examples 1-1 and 1-2
In Example 1-1, using the same material as in Example 1, a fiber base material having a hinge portion and having a skin material adhered thereto was obtained from a plate-shaped resin molded body. Specifically, the fiber base material of Example 1 is again heated by a hot plate press to melt the thermoplastic resin near the surface, and then 40 ° C. until the temperature reaches 25 ° C. together with the skin material set in the molding apparatus. After cooling for 2 seconds, a hinge part was formed and the skin material was bonded. As the skin material, a nonwoven fabric mainly composed of polyethylene terephthalate fibers was used. In Example 1-2, a fiber base material was obtained in the same manner as in Example 1-1 except that the skin material was not adhered.

(2) Example 3-1
In Example 3-1, using the same material as in Example 3, a fiber base material having a hinge portion and having a skin material adhered thereto was obtained from a plate-shaped resin molded body. In Example 3-1, a fiber base material in which the content of aramid fiber X was increased by 10% by mass and the content of kenaf fiber was reduced by 10% by mass from Example 3 was used. The formation method of the hinge part, the material of the skin material, and the bonding method thereof were the same as in Example 1-1.

(3) Example 4-1
In Example 4-1, using the same material as in Example 4, a fiber base material having a hinge part and having a skin material adhered thereto was obtained from a plate-shaped resin molded body. In Example 4-1, a fiber base material in which the content of aramid fiber X was increased by 10% by mass and the content of kenaf fiber was reduced by 10% by mass from Example 4 was used. The formation method of the hinge part, the material of the skin material, and the bonding method thereof were the same as in Example 1-1.

(4) Comparative Examples 1-1 and 1-2
In Comparative Example 1-1, using the same material as in Comparative Example 1, a fiber base material having a hinge part and having a skin material adhered thereto was obtained from a plate-shaped resin molded body. The formation method of the hinge part, the material of the skin material, and the bonding method thereof were the same as in Example 1-1. Comparative Example 1-2 obtained the fiber base material like the said Comparative Example 1-1 except the film intervening between the skin material and the fiber base material. A film made of polyethylene was used.

[4] Hinge durability test The following hinge durability test was performed on the fiber base material obtained in [3] above.
Hinge durability test: The hinge portion was bent and deformed, with the hinge portion not bent and deformed in the initial state, and a part of the fiber-containing resin molded body (the portion corresponding to the second board portion 17) was bent back and forth. This operation was repeated 1000 times, with the operation of returning to the initial state as one set later. And the appearance abnormality of the hinge part at the time of operation | movement 100 times, 150 times, 200 times, and 1000 times was investigated. The operation of bending a part of the fiber-containing resin molded body to the front and back is performed by rotating a part of the fiber base material 150 ° to the surface side to which the skin material is bonded around the hinge part, and then the hinge part is bonded. It was made to turn 85 degrees to the opposite side to the surface made.

[5] Evaluation of Hinge Durability The results of the hinge durability test are shown in the table of FIG. In the table of FIG. 7, the hinge durability was evaluated from the following viewpoints.
○: No significant appearance abnormality △: Slight appearance abnormality ×: Appearance abnormality

  In Comparative Example 1-1, tearing of the skin material was confirmed by 150 bending operations, and the fiber base material was confirmed to be broken by 1000 bending operations. In Comparative Example 1-2, it was confirmed that the skin material was torn by 200 bending operations, and the fiber base material was confirmed to be broken by 1000 bending operations. In Example 1-2, a remarkable appearance abnormality such as the fiber base material being broken was not observed after 1000 bending operations, but a slight appearance defect in which the fibers were partially exposed on the surface was observed. In Example 4-1, a remarkable appearance defect in which the fiber base material was broken by 1000 bending operations was confirmed. In Example 1-1 and Example 3-1, no abnormality in appearance was confirmed up to 1000 times of the hinge durability test.

[6] Discussion In the conventional fiber base material as in Comparative Example 1-1, it is considered that the skin material was torn by 150 bending operations due to the low bending elastic modulus. Further, as in Comparative Example 1-1, in the structure in which the hinge portion is compressed and deformed by the molding die and at the same time, the skin material is directly bonded to the fiber base material, the fiber base material and the skin in the hinge portion Since the adhesiveness with the material is higher than that of the surroundings, it is considered that the stress is concentrated on the part and the skin material is easily torn. In Comparative Example 1-2, the film was interposed between the fiber base material and the skin material, so that no tearing of the skin material was observed in 150 bending operations. This was not sufficient in terms of hinge durability. On the other hand, in each of the fiber base materials containing high strength fibers (PBO fibers or aramid fibers) as in each of the examples, there is no significant abnormality in appearance after 200 bending operations, and Comparative Example 1-1 and Comparative Example 1 It was confirmed that the hinge durability was improved from -2. Moreover, in Example 1-2, although the appearance defect like slight fuzz was produced on the surface of the fiber base material, in Example 1-1, such an appearance because the surface is covered with the skin material. It was found that the defect was not visually recognized and the effect of further suppressing the appearance defect was greater.

  Furthermore, although Example 3-1 and Example 4-1 contain the same material and the same amount of high strength fiber (aramid fiber), Example 4-1 containing acid-modified polypropylene is substantially non-practical. It turned out that hinge durability is inferior from Example 3-1 containing only acid-modified polypropylene. This is presumably because the use of an acid-modified thermoplastic resin having high adhesiveness with kenaf fibers makes the fiber base material hard but brittle and easily breaks due to the load when the hinge portion is bent. On the other hand, in Example 3-1, non-acid-modified thermoplastic resin having low adhesion to kenaf fibers is used while maintaining the elastic modulus of the fiber base material by mixing high-strength fibers as an alternative to kenaf fibers. Thus, it is presumed that the load at the time of bending the hinge portion is released as frictional energy between the kenaf fiber and the non-acid-modified thermoplastic resin, and the breakage of the fiber base material can be suppressed. As a result, in Example 3-1 including only a non-acid-modified thermoplastic resin as a thermoplastic resin and Example 1-1 including another high-strength fiber (PBO fiber), the appearance can be obtained even after 1000 bending operations. It is probable that no abnormality was confirmed.

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

<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 addition to the above embodiment, the contents of vegetable fiber, high strength fiber, and thermoplastic resin can be appropriately changed. Moreover, the fiber base material may further include other components than those described above.
(2) In addition to the above embodiment, the fiber substrate can be manufactured by various manufacturing methods using materials of various materials.
(3) In the said embodiment, although the interior material for vehicles and its manufacturing method were illustrated as a fiber base material and its manufacturing method, a fiber base material should be widely utilized in a building related field etc. besides a motor vehicle related field. Can do. Particularly suitable for interior materials, exterior materials and structural materials for automobiles, railway vehicles, ships and airplanes, etc. Especially as automotive products, suitable for automotive interior materials, automotive instrument panels, automotive exterior materials, etc. It is. Specifically, seat back board, door base material, package tray, pillar garnish, switch base, quarter panel, armrest core material, automotive door trim, seat structure material, seat back board, ceiling material, console box, automotive use Dashboards, various instrument panels, deck trims, bumpers, spoilers and cowlings. Furthermore, it is also suitable for interior materials, exterior materials and structural materials such as buildings and furniture. Specifically, door cover materials, door structure materials, cover materials for various furniture (desks, chairs, shelves, bags, etc.), structural materials, and the like can be given. In addition, it is also suitable as a package, a container (such as a tray), a protective member, and a partition member.
(4) In the said embodiment, although the skin material illustrated the structure adhere | attached on the surface of the hinge part with the thermoplastic resin derived from a fiber base material, it is not restricted to this. For example, the skin material may be bonded to the hinge portion via an intervening layer such as a film. Moreover, the structure by which a hinge part is not covered with the skin material may be sufficient, and either one of the upper surface or the lower surface of a fiber base material may be covered with the skin material. Furthermore, it is possible to appropriately use various materials and properties of the skin material.
(5) In the said embodiment, although the skin material of the both sides of front and back illustrated the structure stuck in the process of forming a hinge part, it is not restricted to this. For example, the skin material on the back side may be attached in the process of forming the preboard from the fiber mat, and the skin material on the front side may be attached in the process of forming the hinge portion (see FIG. 8). In such a configuration, since the skin material on the back side is firmly adhered to the fiber base material as compared with the case where it is stuck in the process of forming the hinge portion, the peel strength can be increased. it can. In this case, the skin material is easily torn along with the crack of the hinge portion, etc., but in this embodiment, since the durability of the hinge portion is increased, it is also suitable for such a manufacturing method. is there.
(6) In the above-described embodiment, the hinge portion is provided at the base end portion of the second board portion, and has been exemplified for ease of displacement in the luggage board and in the luggage compartment, but is not limited thereto. . The hinge part may be provided in a cover part (for example, a map pocket cover) for opening and closing the opening part, a part provided for assembly with other members, or the like. Further, the amount of bending deformation of the hinge portion can be appropriately changed according to the portion where the hinge portion is provided. Furthermore, the structure of the hinge part is not limited to the structure in which the fiber base material is thinned, and a structure having a perforated slit or a preliminary bending process several times can bend and deform from other parts. The structure etc. made easy may be sufficient.

  DESCRIPTION OF SYMBOLS 10 ... Fiber base material (fiber containing resin molding), 10A ... Upper surface (surface of hinge part 15), 10B ... Lower surface (surface of hinge part 15), 15 ... Hinge part, 111 ... First skin material (skin material) 112 second skin material (skin material)

Claims (7)

A fiber-containing resin molded body having a hinge part that can be bent and deformed,
A fiber-containing resin molding containing a thermoplastic resin, a vegetable fiber and a high-strength fiber.   The fiber-containing resin molded body according to claim 1, wherein a surface of the hinge portion is covered with a skin material.   The fiber-containing resin molded product according to claim 2, wherein the skin material is bonded to the surface of the hinge portion by the thermoplastic resin.   The fiber-containing resin molded body according to any one of claims 1 to 3, wherein a tensile elastic modulus of the high-strength fiber is 27 GPa or more.   The fiber-containing resin molding according to any one of claims 1 to 4, wherein the high-strength fiber is at least one selected from aramid fiber, polyparaphenylene benzobisoxazole fiber, carbon fiber, and glass fiber. body.   The content rate of the said vegetable fiber and the said high strength fiber is 20-95 mass% and 1-40 mass% with respect to the whole said fiber containing resin molding, respectively, The any one of Claim 1-5 Item 2. A fiber-containing resin molded article according to item 1.   The fiber-containing resin molded body according to any one of claims 1 to 6, wherein the thermoplastic resin is an olefin resin.

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