JP2020078911A - Composite member and manufacturing method thereof - Google Patents

Abstract

To provide a composite member with a resin binder unit for fixing a wood and a covering material more effectively and its manufacturing method.SOLUTION: A covering material 10 is composed of a cloth constituting a fiber body 12 woven or laminated, and is fixed to a wood 4 by a binder unit 14 filled in the covering material 10 in the state of interposing outside of the wood 4 from front and back surfaces. The binder unit 14 is formed by melting solidification a thermoplastic resin, and includes the fiber body 12 in the state of released from the covering material 10.SELECTED DRAWING: Figure 2

Description

  The present invention relates to a composite member including wood, a coating material that coats the outside of the wood, and a resin binder portion that fixes the coating material to the wood, and a method for manufacturing the same.

  In this type of composite member, a lightweight wooden member and a fiber member excellent in strength are integrated, and are used for various applications such as vehicles. For example, the reinforced plywood disclosed in Patent Document 1 has a plurality of plywood corresponding to wood and a fiber reinforcing material in a laminated state. This fiber reinforcing material is, for example, a member in which glass fiber threads are arranged in a mesh shape, and is used to compensate for the weakness that plywood is weak in tension in the direction orthogonal to the fiber direction (has anisotropy). Be done. When manufacturing a reinforced plywood, a fiber reinforcing material is interposed between plywood coated with an adhesive made of a thermosetting resin, and then the fiber reinforcing material and the plywood are bonded by a method such as hot pressing. In the reinforced plywood produced in this manner, the weakness of the plywood, which is called anisotropy, is supplemented with a fiber reinforcing material to improve the strength such as tensile strength.

  By the way, in the above-mentioned reinforced plywood, since the fiber reinforcing material is interposed between the plywoods, the plywoods are arranged on the outermost side. For this reason, when using the reinforced plywood, it is necessary to consider that the outer plywood does not deteriorate due to external stimuli such as light and water and input of load, and the intended use tends to be limited. Therefore, the composite board of Patent Document 2 has a wood veneer, a kenaf fiber layer, and an adhesive layer made of a thermosetting resin. The kenaf fiber layer is a mat-like member (corresponding to a covering material) formed by weaving and knitting kenaf filaments into a sheet, and has excellent surface smoothness and surface hardness. Then, in the composite board, the kenaf fiber layer is bonded to the front and back surfaces of the wood veneer via the adhesive layers. By thus preventing the front and back surfaces of the wood veneer from being exposed to the outside by the kenaf fiber layer, deterioration of the wood veneer due to external stimulus or the like can be avoided as much as possible.

JP, 7-214506, A JP, 2003-39411, A

  Here, in the above-mentioned products such as the reinforced plywood and the composite board, the plywood and the wood veneer (wood) and the fiber member are fixed only by the adhesive layer provided therebetween. Therefore, the adhesive strength of the adhesive layer has a great influence on the product strength, and there is room for further improvement from the viewpoint of maintaining excellent strength of the product. In other words, from the viewpoint of maintaining the excellent strength of the product, it is necessary to avoid the direct action of external stimulus or the like on the wood due to the deterioration of the adhesive and the peeling of the fiber member. It is possible to use the wood having the highest strength, but this may limit the types of wood that can be used and increase the manufacturing cost of the product. The present invention was created in view of the above points, and an object of the present invention is to fix wood and a covering material with higher performance.

  As a means for solving the above problems, the composite member of the first invention includes wood, a coating material that coats the outside of the wood, and a resin binder portion that fixes the coating material to the wood. In this type of composite member, it is desired that the binder be bonded to the wood and the covering material with higher performance (more firmly, for example). Therefore, the covering material of the present invention is composed of a cloth formed by weaving or laminating a fibrous body, and is fixed to the wood by a binder portion filled in the cloth while sandwiching the outside of the wood from the front and back. Has been done. The binder portion is formed by melting and solidifying the thermoplastic resin, and also includes the fibrous body in a state of being unwound from the covering material. In the present invention, the covering material is fixed to the front and back surfaces of the wood by the binder portion filled in the interior of the wood, so as to minimize the excessive external exposure of the wood. By using a thermoplastic resin having excellent fluidity as the binder portion, the wood and the covering material are fixed to each other with higher performance. That is, when the binder portion is formed, the molten thermoplastic resin flows and moves the fibrous body of the covering material, so that the fibrous body in a state of being melted from the covering material is contained in the binder portion and is applied to the wood. Be locked. Therefore, in the present invention, the covering material can be more firmly fixed to the wood by the adhesive force of the binder portion and the locking force of the fibrous body, which contributes to improving the strength of the composite member. There is.

  A composite member according to a second invention is the composite member according to the first invention, wherein the wood is a plate-like or columnar member, and a front surface part of the wood and a backside of the wood located opposite to the surface part. It has a back surface portion and a side surface portion between the front surface portion and the back surface portion. The binder portion including the fibrous body is fixed to the wood in a state of straddling the front surface portion, the side surface portion, and the back surface portion. In the present invention, the strength of the composite member can be further improved by fixing the binder portion containing the fibrous body to the wood in a state of straddling the front surface portion, the side surface portion, and the back surface portion.

  A composite member according to a third aspect of the present invention is the composite member according to the first or second aspect of the present invention, wherein the binder portion including the fibrous body is fixed to the wood in a state of enclosing the wood. In the present invention, the strength of the composite member can be further improved by enclosing the wood with the covering material and the binder portion containing the fibrous body.

  A composite member of a fourth invention is the composite member of any one of the first invention to the third invention, wherein the thermoplastic resin is a polyolefin resin. In the present invention, by using a polyolefin resin having excellent water resistance as the binder portion, it is possible to avoid excessive deterioration of wood due to water in the binder portion as much as possible.

  A composite member according to a fifth aspect of the present invention is the composite member according to any one of the first to fourth aspects, wherein the binder portion includes a component that absorbs or reflects light. In the present invention, by including a component that absorbs or reflects light in the binder portion, it is possible to avoid excessive deterioration of wood due to light in the binder portion as much as possible.

  A composite member of a sixth invention is the composite member according to any one of the first invention to the fifth invention, wherein the coating material is a nonwoven fabric formed by laminating fibrous bodies. In the present invention, since the non-woven fabric as the covering material has a structure in which the fibrous body can be easily moved by the flow of the thermoplastic resin, the covering material can be more firmly fixed to the wood.

  A method for manufacturing a composite member according to a seventh aspect of the present invention is a method for manufacturing a composite member including wood, a coating material that coats the outside of the wood, and a resin binder portion that fixes the coating material to the wood. In the manufacturing method of the present invention, a molding material is prepared in which a thermoplastic resin is filled into a covering material made of a fabric obtained by woven or knitting a fibrous body and integrated. Then, the placing step and the pressing step are performed to manufacture the composite member while integrating the wood and the covering material with higher performance. That is, in the arranging step, the composite material is formed by arranging the molding material such that the outside of the wood is sandwiched from the front and back in a state where the thermoplastic resin is melted. Then, in the pressurizing step, while pressing the composite molding material in the direction of pressing the covering material against the wood, by solidifying the thermoplastic resin in a molten state, the binder portion formed by solidifying the thermoplastic resin is coated. It is made to adhere to the wood while containing the fibrous material in the state of being disassembled from the wood. In the present invention, the covering material is fixed to the front and back surfaces of the wood by the binder portion filled in the interior of the wood through the arranging step and the pressurizing step, so that excessive external exposure of the wood is suppressed as much as possible. Then, in the pressing step, the molten thermoplastic resin flows to move the fibrous body of the covering material, so that the fibrous body in a state of being released from the covering material is contained in the binder portion and is applied to the wood. Be stopped. Therefore, in the present invention, the covering material can be more firmly fixed to the wood by the adhesive force of the binder portion and the locking force of the fibrous body, which contributes to the improvement of the strength of the composite member.

  The method for producing a composite member according to an eighth aspect of the present invention is the method for producing a composite member according to the seventh aspect, wherein the molding material and the wood are heated in a temperature range equal to or higher than the melting point of the thermoplastic resin in the arranging step. Gradually melt. Then, in the pressurizing step, the thermoplastic resin is gradually solidified by pressurizing the composite molding material in a temperature range below the melting point of the thermoplastic resin. In the present invention, by gradually melting the thermoplastic resin during the arrangement step, it becomes possible to spread the thermoplastic resin to both the covering material and the wood to make it fit, and further heat the wood. By doing so, excess water can be removed. Then, by pressing the composite molding material in the pressing step, the fibrous body can be smoothly moved by the movement of the thermoplastic resin that is familiar with the covering material, and further, the binder portion including the fibrous body is allowed to penetrate into the wood. It can be formed in a state.

  According to the first aspect of the present invention, it is possible to fix the wood and the covering material with higher performance. Further, according to the second invention, the wood and the covering material can be fixed to each other with higher strength. Further, according to the third aspect of the present invention, the wood and the covering material can be fixed to each other with higher strength. Further, according to the fourth aspect of the present invention, the water resistance of the composite member can be enhanced by fixing the wood and the covering material with good performance. Further, according to the fifth aspect, it is possible to improve the light resistance of the composite member by fixing the wood and the covering material with good performance. Further, according to the sixth aspect, the wood and the covering material can be more firmly fixed to each other. According to the seventh aspect, the wood and the covering material can be fixed to each other with higher performance. Moreover, according to the eighth aspect, the wood and the covering material can be fixed to each other with higher performance.

It is a schematic perspective view of a vehicle. It is a schematic perspective view of a composite member. It is a schematic sectional drawing of a part of composite member. It is a schematic perspective view of wood. It is a schematic sectional drawing of the molding material and wood at the time of an arrangement process. It is a schematic sectional drawing of the composite molded material at the time of a pressurization process. It is a schematic sectional drawing of a composite member at the time of completion of a pressurization process. FIG. 9 is a schematic cross-sectional view of a molding material and wood at the time of an arranging step according to Modification 1. 9 is a schematic cross-sectional view of a composite member according to Modification Example 1. FIG. FIG. 11 is a schematic cross-sectional view of a composite member according to Modification 3.

  Hereinafter, modes for carrying out the present invention will be described with reference to FIGS. 1 to 10. In FIG. 1, for convenience, arrow lines indicating the front-rear direction, the left-right direction, and the up-down direction of the vehicle are illustrated. In addition, in FIGS. 2 to 9, arrow lines indicating the front-rear direction, the left-right direction, and the up-down direction of the composite member and the like are appropriately illustrated with reference to a state in which the composite member and its configuration are attached to the vehicle.

  The truck TR shown in FIG. 1 is a vehicle having a body 2T forming a cabin and a luggage carrier 3T on the rear side of the body 2T, and the composite member 2 is installed on the floor side of the luggage carrier 3T. 1 to 3, the composite member 2 is a plate-shaped member having a substantially rectangular shape in a top view and having a predetermined thickness dimension T1, and is used as an exterior material forming a floor surface of the luggage carrier 3T. ing. The composite member 2 is a member in which the wood 4 and the covering material 10 are fixed to each other by the binder portion 14, and various properties are improved by making use of the characteristics of the wood 4 and the covering material 10 (of each configuration). Details will be described later). In this type of structure, it is desired that the binder 4 bond the wood 4 and the covering material 10 to each other with good performance in consideration of the exposure of the composite member 2 to the outside. Therefore, in the present embodiment, the wood 4 and the covering material 10 are fixed to each other with higher performance by the configuration described later. Hereinafter, each configuration of the composite member 2 and a method of manufacturing the same will be described in detail.

[wood]
The wood 4 shown in FIGS. 2 to 4 is a substantially rectangular plate-like member having a predetermined thickness and constitutes the core of the composite member 2. Referring to FIG. 4, the wood 4 includes a front surface portion 5 (upper surface in FIG. 4) that is supposed to be exposed to the outside, and a back surface (lower surface in FIG. 4) opposite to the front surface portion 5. It has a portion 6 and a peripheral surface (four side surface portions 7 a to 7 d) arranged between the front surface portion 5 and the back surface portion 6. The front surface portion 5 and the back surface portion 6 are flat surfaces having substantially the same shape and size, and the outer dimensions of the front and rear and left and right sides of the wood 4 are defined by the outer shapes of the double-sided portions 5 and 6. Further, the peripheral surface of the wood 4 is composed of a front side surface portion 7a on the front side, a rear side surface portion 7b on the rear side, a right side surface portion 7c on the right side, and a left side surface portion 7d on the left side. 2, the thickness dimension T1 of the composite member 2 is defined by the vertical dimensions of the side surface portions 7a to 7d that are the thickness of the wood 4, and the thicknesses of the covering material 10 and the binder portion 14 described later. ..

  Here, the front surface portion 5 and the back surface portion 6 shown in FIGS. 3 and 4 may be appropriately smoothed, but are in a non-smooth state from the viewpoint of promoting the adhesion to the binder portion 14 described later. Is desirable. For example, in the present embodiment, as a method of making the outer surfaces of the respective surface portions 5 and 6 non-smooth, a method of leaving the recessed portion DP caused by the node of the wood 4 is adopted, and this recessed portion DP is, for example, It is a through hole or a non-through hole formed by removing the node. As other non-smoothing methods, a method of leaving roughness after cutting, a rustle, a crack, etc., a method of leaving irregularities (dents, cuts, etc.) accidentally created during cutting, or during or after cutting A method of intentionally providing the unevenness can be exemplified. Further, as a method for smoothing each surface portion 5, 6, surface treatment such as sander finishing (polishing finish), planar finish (smooth finish), canna finish (mirror finish) can be exemplified.

  As the wood 4 shown in FIG. 4, wood 4 collected from coniferous trees such as cedar, cypress and pine, and hardwood such as zelkova and beech can be used. It may be a wood product such as a plate material, laminated wood or laminated wood. Further, the wood 4 is preferably lighter in weight than the covering material 10 and the binder portion 14 (thermoplastic resin) described later. For example, when the specific gravity of the binder portion 14 is 1 or more, the wood 4 having a specific gravity of less than 1 (preferably 0.4 to 0.7) can be used, and among them, a coniferous wood product is appropriately lightweight. Since it is inexpensive, it can be suitably used as the wood 4. Further, the water content of the wood 4 is not particularly limited as long as it has a desired strength, but it can be set to about 8%, and it is more preferable that the wood 4 is dried to be equal to or more than this set value. Here, as a method for adjusting the water content of the wood 4, a method of placing the wood 4 in a room having a room temperature of about 30 degrees and a humidity of about 90% for a predetermined time can be exemplified. It is also possible to adjust the water content in the (arrangement step). As a method of measuring the water content of the wood 4, a method of measuring the water content from the difference between the weight of the wood 4 dried by the above method and the weight of the wood 4 before drying can be exemplified.

[Coating material]
The covering material 10 shown in FIG. 2 and FIG. 3 is a face material made of a cloth (woven cloth, knitted cloth, non-woven cloth) formed by weaving or knitting the fibrous body 12 (in each drawing, for convenience, common to each covering material). The reference numeral 10 is given, and the reference numeral 12 is given only to a specific fibrous body). Then, in the composite member 2, a substantially rectangular covering material 10 can be arranged on each of the front surface portion 5 and the back surface portion 6 of the wood 4, and in the present embodiment, the non-woven covering material 10 having the same configuration is arranged. There is. In this covering material 10, the laminated fibrous bodies 12 are randomly entangled with each other and integrated, and when the covering material 10 is viewed as a whole, since the fibrous bodies 12 are continuously arranged without interruption, It can be considered to be formed of fibers. The method for manufacturing the covering material 10 made of a non-woven fabric is not particularly limited, but typically, after laminating a plurality of fibrous bodies 12 by a dry or wet method, the fibers are mechanically or by a method such as fusion or adhesion. The bodies 12 are entangled with each other. The average fiber length of the fibrous body 12 is not particularly limited as long as a non-woven fabric can be formed, but in the case of the glass fiber described later, it is typically 10 mm or more, preferably 20 mm or more. The fiber diameter (fineness) of the fibrous body 12 is not particularly limited, but for example, the fiber diameter of the glass fiber described later is usually set to 3 to 25 μm, preferably 10 to 23 μm in consideration of strength. In the covering material 10 made of a non-woven fabric, the fibrous bodies 12 are more easily moved than the woven or knitted fabric described later, and many fibrous bodies 12 are locked to the wood 4 in the manufacturing process described later. Can be set.

[Fibrous body]
The material of the fibrous body 12 is not particularly limited as long as it has appropriate strength, and an organic fibrous body or an inorganic fibrous body can be selected or used in combination. As a material for the inorganic fibrous body, a glass fiber having a glass composition such as non-alkali glass, low-alkali glass or alkali-containing glass, PAN-based or pitch-based carbon fiber, ceramic fiber, metal fiber, boron fiber, activated carbon fiber Can be illustrated. Further, as a material of the organic fiber body, aromatic polyamide fibers such as aramid, polyolefin resin fibers such as polypropylene, polyamide resin fibers such as nylon, polyester resin fibers such as polyethylene terephthalate, polybenzazole resin fibers, vinylon fibers, Examples thereof include polyarylate fibers, animal-based or plant-based natural fibers. Among them, the fiber body made of glass fiber, carbon fiber, or aramid fiber has appropriate strength and excellent impact resistance, and thus can be suitably used as the fiber body 12 shown in FIG. is there.

[Another example of coating material]
Here, the coating material can be formed of a woven fabric or a knitted fabric in addition to the nonwoven fabric. When a plurality of coating materials are used, each of the coated materials can be independently formed of the nonwoven fabric, the woven fabric, or the knitted fabric. For example, in a covering material formed by weaving a fibrous body, a plurality of fibrous bodies form threads and are continuous (becomes continuous fibers), and the threads are entangled to form a woven or knitted fabric. There is. For example, in a woven covering material, fibrous yarns forming warps or wefts are regularly entangled to form a woven fabric. Basic structures (plain weave, twill weave, satin weave) and variations thereof can be exemplified as the organization of this type of fabric. Among them, in the case of twill weave and satin weave, the threads are relatively sparsely arranged. As a result, the covering material 10 is easily loosened. Further, in a knitted covering material, yarns made of fibrous bodies in the course direction or the wale direction are regularly entangled to form a knitted fabric, and the knitted fabric is excellent in elasticity and easy to be unraveled as compared with the woven fabric. ing. As the organization of this kind of knitted fabric, the weft knitting basic structure (flat knitting, rubber knitting, pearl knitting) and its changing structure, the warp knitting basic structure (denby knitting, cord knitting, atlas knitting, chain knitting) and its changes An example is an organization. In addition, examples of the knitted fabric forming method include flat knitting, warp knitting, and circular knitting. For example, the knitting fabric can be formed into a tubular shape (cylindrical to enclose wood) by circular knitting described later.

[Binder part]
The binder portion 14 shown in FIGS. 2 and 3 is a resin portion that fixes the covering material 10 to the wood 4 and binds them together. The binder portion 14 contains the covering material 10 and the fibrous bodies 12 in a state of being loosened from the covering material 10 in a randomly dispersed state. Then, a part of the fibrous bodies 12 randomly arranged in the binder portion 14 is in a state of being locked to the wood 4 side, and is configured to contribute to the improvement of the strength of the composite member 2. Such a locked state of the fibrous body 12 can be realized by melting and solidifying a thermoplastic resin having excellent fluidity at the time of melting to form the binder portion 14, as described later. For example, the thermoplastic resin forming the binder portion 14 preferably has a melt flow rate value of 30 g/10 min or more measured according to ISO 1133 under conditions of 230° C. and 21.18 N, and more preferably the same value is 35 g/ It is 10 min or more, more preferably the same value is 40 g/10 min or more. By using the thermoplastic resin having excellent fluidity in this manner, it becomes possible to cause the thermoplastic resin to flow so that the coating material 10 can be melted by the manufacturing method described later. Then, the covering material 10 is loosened and the entanglement between the fibrous bodies 12 is loosened, so that the fibrous bodies 12 are in a state of being easily moved toward the wood 4 side. In the case of a resin having an extremely small melt flow rate, the resin does not flow sufficiently during the manufacturing process described below, and the fibrous body 12 is less likely to move to the wood 4 side.

  As the above-mentioned thermoplastic resin, polyolefin resin such as polypropylene (details will be described later), aromatic polyamide resin such as aramid, polycarbonate resin, polyethylene terephthalate, polybutylene terephthalate, poly(ethylene-2,6-naphthalate), nylon ( Polyamide resin such as polyamide), polyurethane resin (thermoplastic type), polyphenylene sulfide resin, propylene-ethylene copolymer, polystyrene resin, vinyl aromatic monomer and (meth)acrylic acid alkyl ester having lower alkyl group And (meth)acrylic resins such as terephthalic acid-ethylene glycol-cyclohexanedimethanol copolymer and polymethylmethacrylate. In the present embodiment, these thermoplastic resins may be used alone or in combination of two or more so as to have desired fluidity at the time of melting.

[Polyolefin resin]
Since the polyolefin resin has excellent water resistance, it can be suitably used as a thermoplastic resin. Here, the type of the polyolefin resin is not particularly limited as long as a predetermined water resistance can be obtained, and a homopolymer of a monomer or a copolymer of two or more types of monomers (random copolymer, block copolymer, Alternating copolymers and graft copolymers) can be appropriately selected and used. For example, as polypropylene (polypropylene resin), a polymer having propylene as a main constituent component can be used, and a propylene homopolymer or a copolymer with another α-olefin can be appropriately selected and used. In addition to propylene, ethylene, 1-butene, isobutene, 4-methyl-1-butene, 1-pentene, 3-methyl-1-pentene, 1-hexene, 1-heptene, 1-octene can be exemplified as the monomer. ..

[Additive (Component that absorbs or reflects light)]
Further, the binder portion 14 shown in FIGS. 2 and 3 can contain, as an additive, a component that contributes to improving the quality and performance of the composite member 2. Examples of this type of additive include light stabilizers, antioxidants, heat stabilizers, flame retardants, metal deactivators, antistatic agents, dispersants, lubricants, and acid-modified polypropylene. The binder portion 14 preferably contains a light resistance agent, an antioxidant, or a heat stabilizer in order to improve the weather resistance of the coating material 10, and above all, absorbs or reflects light (ultraviolet rays, visible rays, infrared rays). It is preferable to include a lightproofing agent. Examples of this type of light-proofing agent include dyes (pigments and dyes), ultraviolet absorbers, infrared absorbers, fillers, and light stabilizers. And as a pigment, carbon compound such as carbon black, benzylidene compound, azo compound, indole compound, azomethine compound, xanthene compound, phthalocyanine compound, triphenylmethane compound, anthraquinone compound, oil-soluble phthalein dye, oil-soluble Examples include triallylmethane dye derivatives. Examples of the ultraviolet absorber include benzotriazole-based, benzoate-based, benzophenone-based, and triazine-based ultraviolet absorbers. Examples of the infrared absorber include lanthanum hexaboride, cesium tungsten oxide, and various dyes. Examples of the filler include metal fillers such as titanium oxide and zirconium oxide, inorganic fillers such as mica and calcium carbonate, and organic fillers such as wood powder. As the light stabilizer, a hindered amine-based light stabilizer can be exemplified.

[Composite member manufacturing method]
In the method for manufacturing the composite member 2 shown in FIG. 2, with reference to FIGS. 5 to 7, the wood 4 and the molding material 20 (details described later) in which the covering material 10 and the thermoplastic resin 14X are integrated are prepared, The arrangement step and the pressurizing step described below are performed. For example, in the present embodiment, a plywood material of softwood can be prepared as the wood 4 shown in FIG. 5, and the plywood material is relatively inexpensive and has a low specific gravity (typically 0.4 to 0.7). Then, in the wood 4 made of plywood material, a plurality of or a single recessed portion DP is intentionally left in the front surface portion 5 and the back surface portion 6 to be in a non-smooth state.

[Molding material]
Further, the molding material 20 shown in FIG. 5 is a member formed by filling the covering material 10 with the thermoplastic resin 14X so as to be integrated, and can be arranged on the front and back surfaces (5, 6) of the wood 4. (In FIG. 5, for convenience, a common reference numeral 20 is given to each molding material). As the molding material 20 of this type, a molding material 20 having the performance required for the composite member 2 can be used, and a molding material 20 that is uniquely molded may be used, or a commercially available molding material 20 may be used. May be. For example, a glass mat reinforced thermoplastic (GMT or GMTex (registered trademark)) manufactured by Quadrant Plastic Composite, a reinforced thermoplastic (CFRTP or GFRTP, trade name: texex (registered trademark)) manufactured by Bond Laminates It can be used preferably. In this type of molding material 20, the thermoplastic resin 14X is solidified in a state where the fibrous body 12 forming the covering material 10 is filled (completely impregnated state), and the solidified thermoplastic resin 14X is formed. Are fixed to and integrated with each fibrous body 12. The weight ratio of the covering material 10 (fibrous body 12) in the entire molding material 20 can be appropriately set according to the performance required for the composite member 2, and is typically set in the range of 20 to 80% by weight, and From the viewpoint of securing the property, it is desirable to set it in the range of 30 to 70% by weight. The coating material 10 in the molding material 20 is typically buried in the solidified thermoplastic resin 14X, but if the performance of the composite member 2 does not decrease excessively, a part of the coating material 10 is exposed to the outside. It may be exposed.

[Placement process]
In the arranging step shown in FIG. 5, the molding material 20 is arranged so as to sandwich the outside of the wood 4 from the front and back in a state where the thermoplastic resin 14X is melted to form the composite molding material 22 shown in FIG. In this arranging step, the thermoplastic resin 14X can be gradually melted by heating the molding material 20 and the wood 4 in a temperature range equal to or higher than the melting point of the thermoplastic resin 14X. For example, referring to FIG. 5, after the molding material 20 is arranged on the front surface portion 5 and the back surface portion 6 of the wood 4, these are placed in the oven 30 heated to a predetermined temperature, and the molding material 20 The thermoplastic resin 14X is heated until it is entirely melted. The temperature in the oven 30 can be set to a temperature range of 190°C to 260°C when polypropylene (the melting point in the case of homopolymerization is 160 to 165°C) is used as the thermoplastic resin 14X, and it is typically about It can be set to 230°C. In this way, by heating the molding material 20 and the wood 4 to gradually melt the thermoplastic resin 14X, each of the covering material 10 and the wood 4 can be melted without solidifying the fully melted thermoplastic resin 14X. The surface parts (5, 6) can be sufficiently spread and made to fit. Then, as the thermoplastic resin 14X becomes soft in the state of being familiar with the covering material 10, the entanglement between the fibrous bodies 12 of the covering material 10 becomes loose, and these become easy to be melted. In addition, in the arrangement step, by heating the wood 4, excess water and volatile components in the wood 4 can be sufficiently removed, and the water content of the wood 4 is adjusted at the same time as the arrangement step. be able to. Thus, in the arranging step, the composite molding material 22 shown in FIG. 6 is formed from the wood 4 and the molding material 20. In the composite molding material 22, the wood 4 and the molding material 20 are separated by the sufficiently molten thermoplastic resin 14X. It is moderately tied.

[Pressure process]
Next, in the pressing step shown in FIG. 6, the thermoplastic resin 14X in a molten state is solidified while pressing the composite molded material 22 in the direction of pressing the covering material 10 against the wood 4 (vertical direction in FIG. 6). .. In this pressurizing step, the thermoplastic resin 14X can be gradually solidified by pressing the composite molding material 22 in a temperature range lower than the melting point of the thermoplastic resin 14X. For example, referring to FIG. 6, a mold 32 for press molding is prepared, and the composite molded material 22 is set in a board-shaped cavity 32 a of the mold 32. The cavity 32a may have a front, rear, left, and right dimensions larger than those of the composite molded material 22 (may be cavities for forming ribs), or may have substantially the same dimensions as the composite molded material 22 (ribs). It may be a non-forming cavity). For example, in the rib forming cavity 32a as in the present embodiment, the thermoplastic resin 14X is allowed to flow around the side surface portions 7a, 7b of the wood 4 and the like. When the polypropylene is used as the thermoplastic resin 14X, the temperature inside the mold 32 can be set to a temperature range of 100° C. or lower, and typically can be set to about 50° C. Further, the pressure of the mold 32 is preferably set to a low pressure so as not to excessively crush the wood 4 in the thickness direction. For example, by setting the pressure of the die 32 to 1 MPa or less, the crushing of the wood 4 can be avoided as much as possible, and typically the pressure can be set in the range of 0.005 MPa to 1 MPa.

  Then, as shown in FIG. 6, by pressing the composite molded material 22, the molten thermoplastic resin 14X gradually spreads along the outer surface of the wood 4. At this time, due to the movement of the molten thermoplastic resin 14X which is filled in the covering material 10 and familiar with the respective fibrous bodies 12, the respective fibrous bodies 12 in a state of being melted from the covering material 10 are transferred from the covering material 10 to the wood 4. Move towards. Then, in the front surface portion 5 and the back surface portion 6 of the wood 4, the thermoplastic resin 14X in the corresponding covering material 10 is solidified while including the fibrous body 12 to form the binder portion 14. At this time, part of the binder portion 14 acts as an anchor by being filled and fixed in the recessed portion DP of the front surface portion 5 and the recessed portion DP of the back surface portion 6. Then, the fibrous body 12 included in the binder portion 14 enters and is interlocked with the gap between the fibrous materials of the wood 4 or the recessed portion DP, and the portion of the binder portion 14 serving as an anchor is also inside each fibrous body 12. It will be strengthened by entering. Further, the thermoplastic resin 14X including the fibrous body 12 shown in FIG. 6 also wraps around from the front surface portion 5 and the back surface portion 6 to some or all of the side surface portions 7a to 7d of the wooden piece 4 shown in FIG. The binder portion 14 can be formed by solidifying. Further, in the present embodiment, the thermoplastic resin 14X is sufficiently melted in the arrangement step, so that the thermoplastic resin 14X can be sufficiently spread by contacting the wood 4 even under a relatively low pressure condition. Has become. Furthermore, since the wood 4 is sufficiently dried in the arranging step, it is possible to avoid a situation where gas (water vapor or the like) is generated from the wood 4 in the pressurizing step to cause defective molding as much as possible. In the composite member 2 of FIG. 7 manufactured in this manner, the covering material 10 can be firmly fixed to the wood 4 by the adhesive force of the binder portion 14 and the locking force of the fibrous body 12, which contributes to the improvement of strength. Has become.

  Here, in the pressurizing step shown in FIG. 6, by adjusting the shape and pressure of the cavity and the pressurizing time, it is possible to adjust the coating range (extending range) of the thermoplastic resin 14X on the wood 4. For example, by using a board-shaped cavity for forming no ribs, the thermoplastic resin 14X can be spread over only the front surface portion 5 and the back surface portion 6 and fixed to the wood 4 (see a modified example described later in FIG. 9). See). In the present embodiment, by using the rib forming cavity 32a shown in FIG. 6, the thermoplastic resin 14X is wrapped around the wood 4 as shown in FIG. The timber 4 can be fixed by being spread over the places 7a, 7b and the like. In such a case, the binder portion 14 including the fibrous body 12 is solidified in a state of straddling the front surface portion 5, the side surface portions 7a, 7b, etc. of the wood 4 and the back surface portion 6. Then, by connecting the covering materials 10 arranged on the front surface portion 5 and the back surface portion 6 with the binder portions 14 such as the side surface portions 7a and 7b, the binder portion 14 portion acts as a rib RB, and the composite member 2 The strength of can be further improved. Further, by wrapping the wood 4 in the binder portion 14 including the fibrous body 12 and the covering material 10, it is possible to preferably prevent the wood 4 from being exposed to the outside and further improve the strength of the composite member 2.

[Example of using composite members]
In the present embodiment, the composite member 2 shown in FIGS. 1 to 3 and 7 is installed on the floor side of the loading platform 3T of the truck TR shown in FIG. At this time, the composite member 2 can be installed on the luggage carrier 3T in a state where the covering material 10 portion covering the surface portion 5 of the wooden piece 4 is exposed to the outside (upper side of each drawing). The composite member 2 may be appropriately cut according to the shape of the luggage carrier 3T, and in this case, part of the wood 4 (for example, the front side surface portion 7a) may be exposed to the outside. Even in such a case, since the other side surface portions 7b to 7d in the non-cutting state are covered with the binder portion 14 (rib RB) including the fibrous body 12, excessive reduction in strength due to cutting is avoided as much as possible. It is possible to do. The composite member 2 serving as the exterior material of the luggage carrier 3T has both the lightness of the wooden piece 4 and the strength of the covering material 10, and is in a state where the external exposure of the wooden piece 4 is avoided as much as possible. Further, the composite member 2 has a structure having excellent strength and durability because the covering material 10 is firmly fixed to the wood 4 at the binder portion 14 including the fibrous body 12. At this time, by using a polyolefin resin having excellent water resistance as the binder portion 14, the binder portion 14 can avoid excessive deterioration of the wood 4 due to water. In addition, by including a component that absorbs or reflects light in the binder portion 14, it is possible to avoid excessive deterioration of the wood 4 due to light in the binder portion 14 as much as possible. In this way, in the composite member 2, since the covering material 10 and the wood 4 are firmly fixed to each other by the binder portion 14, it is possible to improve various performances such as strength without depending on the kind of the wood 4 as much as possible. it can. Therefore, even if the wood 4 is selected and used for the composite member 2 while paying attention to lightness and price, the composite member 2 can be appropriately used as an exterior material, and the flexibility of selection of the wood 4 is increased. It is possible.

  As described above, in the present embodiment, the covering material 10 is fixed to the front and back surfaces of the wooden piece 4 by the binder portion 14 filled in the inside thereof, whereby excessive external exposure of the wooden piece 4 is suppressed as much as possible. Then, by using a thermoplastic resin having excellent fluidity as the binder portion 14, the wood 4 and the covering material 10 are firmly fixed to each other. That is, when the binder portion 14 is formed, the molten thermoplastic resin having a predetermined melt flow rate flows to move the fibrous body 12 of the covering material 10, whereby the fibrous body 12 in a state of being unraveled from the covering material 10 is formed. , The state of being included in the binder portion 14 is locked to the wood 4. Therefore, in the present embodiment, the covering material 10 can be more firmly fixed to the wood 4 by the adhesive force of the binder portion 14 and the locking force of the fibrous body 12, thus improving the strength of the composite member 2. It is designed to contribute to.

  Further, in the present embodiment, the binder portion 14 including the fibrous body 12 is fixed to the wood 4 in a state of straddling the front surface portion 5, the side surface portions 7a to 7d, and the back surface portion 6, so that the composite member 2 The strength of can be further improved. Further, in the present embodiment, the strength of the composite member 2 can be further improved by wrapping the wood 4 with the covering material 10 and the binder portion 14 including the fibrous body 12. Further, in the present embodiment, by using the polyolefin resin having excellent water resistance as the binder portion 14, it is possible to avoid excessive deterioration of the wood 4 due to water in the binder portion 14 as much as possible. Further, in the present embodiment, by including a component that absorbs or reflects light in the binder portion 14, it is possible to avoid excessive deterioration of the wood 4 due to light in the binder portion 14 as much as possible. Further, in the present embodiment, since the non-woven fabric as the covering material 10 has a configuration in which the fibrous body 12 can be easily moved by the flow of the thermoplastic resin, the covering material 10 can be more firmly fixed to the wood 4. it can. Therefore, according to the present embodiment, the wood 4 and the covering material 10 can be fixed to each other with higher performance.

  Further, in the manufacturing method of the present embodiment, the covering material 10 is fixed to the front and back surfaces of the wood 4 by the binder portion 14 filled in the interior of the wood 4 through the arrangement step and the pressurizing step. The external exposure of is suppressed as much as possible. Then, in the pressurizing step, the molten thermoplastic resin 14X having a predetermined melt flow rate flows and moves the fibrous body 12 of the covering material 10, whereby the fibrous body 12 in a state of being unraveled from the covering material 10, It is contained in the binder portion 14 and is locked to the wood 4. Therefore, in the present invention, the coating material 10 can be more firmly fixed to the wood 4 by the adhesive force of the binder portion 14 and the locking force of the fibrous body 12, which contributes to improving the strength of the composite member 2. Has become. Then, in the present embodiment, the thermoplastic resin 14X is gradually melted during the disposing step, so that the thermoplastic resin 14X can be spread over both the covering material 10 and the wood 4 and be made to fit into them. Then, by heating the wood 4, excess water can be removed. Then, by pressing the composite molded material 22 in the pressing step, the fibrous body 12 can be smoothly moved by the movement of the thermoplastic resin 14X that is familiar with the covering material 10, and further, the binder portion 14 including the fibrous body 12, It can be formed in a state of invading the wood 4.

[Modification 1 (another example of the manufacturing method)]
Here, the manufacturing method of the composite member can take various procedures in addition to the above procedure. For example, in the modified example 1, the arrangement process and the pressurization process are performed using the press machine 34 including the lower die punch 34a and the upper die 34b shown in FIG. Then, in the arranging step, the molding material 20 and the wood 4 are set between the lower die punch 34a and the upper die 34b which are heated to an appropriate temperature. The shim 35 (spacer) prepared at this time is similarly set between the lower die punch 34a and the upper die 34b and installed around the molding material 20 and the wood 4. 2 and 8, the shim 35 is a plate-like or columnar member having a thickness dimension T2 (T2=T1) substantially the same as that of the composite member 2, and the pressure setting set in the arranging step. It is made of highly rigid material such as steel so that its shape does not change. Then, in the arranging step, the molding material 20 and the wood 4 are heated while being sandwiched between the lower die punch 34a and the upper die 34b. At this time, with the shim 35, the thermoplastic resin 14X can be gradually melted in a state where an excessive pressure is not applied to the molding material 20 and the wood 4 as much as possible. Then, in the pressing step, the shim 35 is removed from the pressing machine 34, and the composite molded material is pressed under the same conditions as in the embodiment. In the composite member 2 of FIG. 9 manufactured in this manner, the front surface portion 5 and the back surface portion 6 of the wood 4 are in a state of being covered with the covering material 10 and the binder portion 14. The parts 7a to 7d are exposed to the outside. Even in such a configuration, by covering the front surface portion 5 and the rear surface portion 6 with the covering material 10 and the binder portion 14 as shown in FIG. 9, it is possible to avoid excessive external exposure of the wood 4. Becomes

[Modification 2 (other example of melting timing and pressure setting of thermoplastic resin)]
It is also possible to heat only the molding material until the thermoplastic resin melts prior to the disposing step. For example, in Modification 2, referring to FIG. 5, only the molding material 20 is heated until the thermoplastic resin 14X is melted. Next, this molding material 20 is arranged so as to sandwich the outside of the wood 4 from the front and back in the arranging step to form the composite molding material 22 shown in FIG. Then, referring to FIG. 6, in the pressing step, the molten thermoplastic resin 14X is solidified while pressing the composite molded material 22 in the direction of pressing the molded material 20 against the wood 4. At this time, the pressure of the die 32 is preferably set to a high pressure (for example, a pressure of 15 MPa or more) when the wood 4 is wrapped in the binder portion 14. Thus, also in this modification, the binder portion 14 formed by solidifying the thermoplastic resin can be fixed to the wood 4 while including the fibrous body 12 in a state of being unwound from the covering material 10. In this modification, by heating the molding material 20 in advance, the time required for the arranging step can be shortened and the load on the wood 4 due to heating can be reduced as much as possible. Such a configuration is suitable when using the sufficiently dried wood 4. Further, by crushing the wood 4 appropriately in the thickness direction by the high pressure, it is possible to reduce the thickness of the composite member 2. Also in this modification, the thermoplastic resin 14X is spread only to the front surface portion 5 and the back surface portion 6 by using a board-shaped cavity for forming no ribs or reducing the pressure or the pressurizing time. It is also possible to fix it to the wood 4.

[Modification 3 (another example of the covering material)]
Further, the structure of the composite member can be various structures other than the above structure. For example, in a composite member 2A according to Modification 3 shown in FIG. 10, a cylindrical knitting covering material 10A is used. In this composite member 2A, since the tubular covering material 10A is arranged and fixed to the front surface portion 5, the back surface portion 6, the side surface portions 7a, 7b, etc. of the wood 4 without interruption, the structure further contributes to the improvement of strength. Has become.

[Test example]
Hereinafter, the present embodiment will be described based on test examples, but the present invention is not limited to the test examples. In this test, as the molding material of the example, a glass mat reinforced thermoplastic made by Quadrant Plastic Composite Co., Ltd. (coating material: non-woven fabric, glass fiber content rate: 40% by weight, thermoplastic resin: polypropylene ) Was used. In addition, as a molding material of the comparative example, the content rate of glass fiber reinforced thermoplastic made by Prime Polymer Co., Ltd. (raw material: pellets made by Japan Polypro Co., Ltd. (trade name: Funkster (registered trademark)), fiber body made of glass fiber : 40% by weight, thermoplastic resin: polypropylene) was used. The molding material of the comparative example is different from the embodiment in that the glass fibers are dispersed in the thermoplastic resin in a discontinuous state. Then, the impact resistance (Charpy impact value) of the molding materials of Examples and Comparative Examples was measured according to "ISO 179-1".

[Results and Discussion]
The Charpy impact value of the molding material of the comparative example was 21.3 kJ/m ² . On the other hand, the Charpy impact value of the molded material of the example was 82 kJ/m ² , and the impact resistance was remarkably improved as compared with the comparative example. From these results, it was found that the molding material using the non-woven fabric (continuous fiber) coating material as in the example has excellent strength. Therefore, it was easily inferred that the performance of the composite member could be further improved by fixing the covering material and the wood with good performance at the binder portion as in the present embodiment.

  The present embodiment is not limited to the above-described embodiment, and various other embodiments can be adopted. For example, in this embodiment, the configuration (shape, size, installation position, intended use, etc.) of the composite member 2 is illustrated, but the configuration of the composite member is not limited. For example, the composite member can be used not only for the floor surface (exterior material) of a cargo bed, but also for various exterior materials and interior materials of vehicles, and also for structures such as houses. Further, the composite member can have various shapes such as a plate shape and a column shape, and the shape of the composite member is set according to the intended use. Further, the front surface portion and the back surface portion of the composite member may be flat surfaces, curved surfaces or bent surfaces.

  Further, in the present embodiment, the configurations of the wood 4, the covering material 10 and the like and the binder portion 14 are exemplified, but the configurations are not limited to these. Wood can take various shapes and sizes depending on the application of the composite member. Further, the covering material and the binder portion can cover at least one of the side surface portions as well as the front surface portion and the back surface portion of the wood. It is also possible to provide a through hole in the wood and fill the through hole with a binder portion. The binder portion may contain a light resistance agent, or may be covered with a protective layer containing a light resistance agent.

  Further, although the manufacturing method of the composite member is illustrated in the present embodiment, the manufacturing method is not limited to this. For example, in the arranging step, plural or singular molding materials can be arranged on the front and back sides of the outer side of the wood, and at this time, molding materials having different configurations (for example, different thicknesses and shapes) can be arranged for the front and back surfaces. The configurations of the manufacturing method according to the embodiment and the modified example can be appropriately combined and used. The configuration of the device used in each step can be changed as appropriate.

TR truck 2T body 3T cargo bed 2 composite member 4 wood 5 front surface portion 6 back surface portion 7a front side surface portion 7b rear side surface portion 7c right side surface portion 7d left side surface portion DP recessed portion RB rib 10 coating material 12 fiber body 14 binder portion 14X thermoplastic Resin 20 Molding material 22 Composite molding material 30 Oven 32 Mold 32a Cavity 34 Pressing machine 34a Lower mold punch 34b Upper mold die 35 Shim 2A Composite member 10A of Modification 3 Coating material of Modification 3

Claims (8)

In a composite member comprising wood, a coating material for coating the outside of the wood, and a resin binder part for fixing the coating material to the wood,
The covering material is composed of a cloth formed by woven or laminating a fibrous body, and the wood portion is filled with the binder in a state where the outside of the wood material is sandwiched from the front and back sides. Is fixed to
The binder is a composite member that is formed by melting and solidifying a thermoplastic resin, and that includes the fibrous body in a state of being unwound from the coating material. The wood is a plate-shaped or columnar member, and a front surface part of the wood, a back surface part opposite to the front surface part and a back side of the wood, the front surface part and the back surface part. And a side portion between
The composite member according to claim 1, wherein the binder portion including the fibrous body is fixed to the wood in a state of straddling the front surface portion, the side surface portion, and the back surface portion.   The composite member according to claim 1 or 2, wherein the binder portion including the fibrous body is fixed to the wood in a state of enclosing the wood.   The composite member according to claim 1, wherein the thermoplastic resin is a polyolefin resin.   The composite member according to claim 1, wherein the binder portion includes a component that absorbs or reflects light.   The composite member according to any one of claims 1 to 5, wherein the covering material is a nonwoven fabric formed by laminating the fibrous bodies. In a method of manufacturing a composite member comprising wood, a coating material for coating the outside of the wood, and a resin binder part for fixing the coating material to the wood,
In the covering material made of a fabric obtained by woven or laminating a fibrous body, a molding material in which a thermoplastic resin is filled and integrated is prepared,
An arrangement step of forming the composite material by arranging the molding material in a state where the thermoplastic resin is melted so as to sandwich the outside of the wood from the front and back sides,
While pressing the composite molding material in the direction of pressing the covering material against the wood, by solidifying the thermoplastic resin in a molten state, the binder portion formed by solidifying the thermoplastic resin, A method of manufacturing a composite member, comprising: a pressing step of fixing the fibrous body in a state of being loosened from a covering material onto the wood. In the disposing step, by heating the molding material and the wood in a temperature range of the melting point of the thermoplastic resin or more, gradually melting the thermoplastic resin,
The method for producing a composite member according to claim 7, wherein in the pressurizing step, the thermoplastic resin is gradually solidified by pressurizing the composite molding material in a temperature range lower than the melting point of the thermoplastic resin. ..

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