JP2023072302A - Board member and method for manufacturing board member - Google Patents

Abstract

To provide a board member, which is a board member comprising a substrate material, a fiber layer and a film material, and in which unevenness on the film due to natural fiber is suppressed, and the fiber layer is reliably adhered to the film material and the substrate material.SOLUTION: The board member has a plate-shaped substrate material 42, a fiber layer 46 composed mainly of a natural fiber 60 and bonded to the surface side of the substrate material 42, and a film material 44 bonded to the surface side of the fiber layer 46 and constituting a design surface, and in which the fiber layer 46 has a configuration in which a first fiber 60, which is a natural fiber, and a second fiber 62, which is a fiber thinner than the fiber diameter of the natural fiber 60, are entangled to form a mat-shape.SELECTED DRAWING: Figure 3

Description

TECHNICAL FIELD The present invention relates to a board member having a fiber layer using natural fibers, and to a method for manufacturing the board member.

BACKGROUND ART Conventionally, there has been known a molded article having a configuration in which entangled plant fibers such as kenaf are bound by a thermoplastic resin. This molded article contains plant fibers for the main purpose of weight reduction, and a member manufactured using this molded article is a vehicle interior material described in Patent Document 1 below. , The surface is often covered with a skin material or a resin surface material and used in an invisible state. On the other hand, as in Patent Document 2 below, a molded article containing plant fibers as described above is employed for design surfaces such as interior materials of vehicles and furniture to realize articles with fiber pattern designs. is being considered. In addition, the vehicle interior material described in Patent Document 1 has a configuration in which a film decorated by printing is adhered to a translucent base material, and a lighting means is arranged on the back side of the film. By irradiating light from the back side, it is possible to highlight designs such as patterns that are not expressed when not illuminated.

JP 2015-003662 A Japanese Patent Application Laid-Open No. 2021-160118

As in the above Patent Documents 1 and 2, in the design surface of various articles, etc., the feeling of natural fibers is expressed by a structure in which natural fibers are directly visible or a structure in which light is irradiated from the back side to make the natural fibers stand out. is being considered. The inventors of the present application have developed a board material in which a design material composed of a fiber layer formed in a mat shape using natural fibers and a film material adhered to the surface side of the fiber layer is attached to a plate-like base material. It was investigated. However, there is a problem in that the design surface of the film material has irregularities due to the natural fibers, impairing the feeling of the natural fibers. In addition, the surface of the fiber layer desirably has non-uniform natural fibers in order to express the feeling of natural fibers. There was a problem that the variation of

The present invention has been made in view of such circumstances, and provides a board member that suppresses irregularities on a film due to natural fibers and that reliably bonds a fiber layer to a film material and a substrate. is the subject.

In order to solve the above problems, the board material of the present invention is
a plate-like substrate;
a fiber layer composed mainly of natural fibers and bonded to the surface side of the substrate;
a film material that is adhered to the surface side of the fiber layer and forms a design surface,
The fiber layer is characterized in that the first fibers, which are natural fibers, and the second fibers, which are fibers thinner than the fiber diameter of the natural fibers, are intertwined to form a mat.

In the board member of this configuration, the second fibers with a small fiber diameter are entangled around the natural fibers with a relatively large fiber diameter, so that there is a large gap between the natural fibers and the film material and between the natural fibers and the base material. By interposing the second fibers in the film material, it is possible to suppress the occurrence of irregularities in the film material due to the natural fibers. In addition, in the board member with this structure, the presence of the second fibers increases the surface area, that is, the bonding area increases, and the second fibers are dispersed even in places where there are few natural fibers. It is possible to suppress the variation in the adhesive strength at the time, and it is possible to reliably bond the fiber layer to the film material and the base material.

For example, when natural fibers are used as the base material for the purpose of reducing the weight of the interior material for vehicles, the fibers of the natural fibers are bonded with a thermoplastic resin to form a plate-like molded body. On the other hand, the "fiber layer" in the board material of this configuration is not bound by the thermoplastic resin, so that the shape can be changed relatively freely. That is, the fiber layer can be adhered to substrates of various shapes. The "fiber layer" in the board member having this configuration may be made of one or more kinds of natural fibers, or may be made of a mixture of synthetic fibers.

The "base material" of this configuration is not limited to a planar one, and a curved shape or a shape having unevenness can be adopted. Further, for example, when a design material composed of a film material and a fiber layer is attached to a base material, the second fiber layer must be present even when the design material is attached to a portion extending in the vertical direction of the base material. Therefore, it is possible to prevent the applied adhesive from dripping down and to firmly adhere the design material to the base material.

In the above configuration, the first fibers may have a fiber diameter of 80 μm or more and 100 μm or less, and the second fibers may have a fiber diameter of 10 μm or more and 30 μm or less.

The board member having this configuration is suitable for increasing the adhesiveness of the fiber layer because the second fibers are easily entwined with the first fibers.

In the above configuration, the fiber layer may have a mass per unit area of 8 g/m ² or more and 20 g/m ² or less.

For example, when a natural fiber is used as a base material for the purpose of reducing the weight of a vehicle interior material, the natural fiber is bound with a thermoplastic resin to form a plate-like molded body. The mass per unit area (basis weight) of the molded product is about 400 to 600 g/m ² . The fiber layer used for the board member with this structure has a very small weight per unit area compared to when it is used as such a base material, and is suitable for conforming to articles of various shapes. . In addition, in this structure, the board member has a base material and a film base material formed from a material having optical transparency, and light is irradiated from the back side to emboss the natural fibers of the fiber layer on the surface of the film material. It is suitable for a configuration that allows In the case of such a structure, the weight of the fiber layer is preferably ^as small as possible ^. is desirable.

In the above configuration, the content of the second fibers in the fiber layer may be 20% or more and 50% or less.

In order to express the feeling of natural fibers on the surface layer when light is irradiated from the back side, it is desirable that the number of natural fibers is as large as possible. At the same time, the natural fiber feel can be fully expressed by the first fibers. In addition, it is more desirable that the content of the second fiber is 25 to 35%.

In the above structure, the film material may be made of a light-transmitting material, and a fiber pattern may be printed on the surface thereof, and the base material may be made of a light-transmitting material.

The board member having this structure expresses a feeling of natural fibers by means of the fiber pattern provided on the surface of the film material when light is not irradiated from the back side. On the other hand, when light is irradiated from the back side, the fiber pattern provided on the film material is partly blurred or disappears due to the light, but the natural The fibers stand out on the surface of the film material, making it possible to express the feeling of natural fibers. From the standpoint of expressing the feel of natural fibers, this fiber layer is preferably a so-called non-woven fabric and is preferably not needle-punched.

The said structure WHEREIN: A said 2nd fiber can be made into the resin fiber which has a light transmittance.

In the board member having this structure, since the second fibers have light transmittance, light is irradiated from the back side to make the natural fibers of the fiber layer stand out on the surface of the film material. The adhesive force to the film material and the base material can be increased while the natural fiber feel of the first fiber is emphasized without protruding on the surface of the material.

In the above configuration, the fiber layer is formed such that the first fibers are aligned in a specific direction, and the fiber pattern of the film material is a pattern that is aligned in the specific direction. It can be configured as

As described above, in the case of a configuration in which light is irradiated from the back side to make the natural fibers of the fiber layer stand out on the surface of the film material, a visible part of the fiber pattern printed on the film material, The natural fibers of the fiber layer, which are exposed by the light, are superimposed and visible. According to the board member of this configuration, the directions of the printed fiber patterns and the raised natural fibers are aligned, so that the image visually recognized when light is irradiated from the back side does not cause a sense of incompatibility. High designability can be secured.

In order to solve the above problems, the method for manufacturing a board member of the present invention comprises:
a fibrous web forming step of forming a fibrous web with the first fibers and the second fibers in an amount that is at least twice the target mass per unit area in the fibrous layer;
a film material adhering step of adhering the two film materials to both surfaces of the fiber web;
A design material forming step of forming two pieces of design material in which the fiber layer is laminated on the film material, including a separation step of separating one of the two film materials from the other by peeling it off;
A board member forming step of forming the board member by bonding the design material to the surface of the base material;
characterized by having

While the natural fibers, which are the first fibers, are relatively straight fibers, the second fibers, which have a small fiber diameter, are often crimped compared to the first fibers. In the separation step of the manufacturing method of the board member having this configuration, when the two film materials are peeled off from each other, the second fibers tend to stand up with respect to the film material. As a result, the fiber layer tends to be in a state in which the second fibers extend from the first fibers to the opposite side of the film material, thereby securing an adhesive surface to the base material and increasing the adhesive strength to the base material. can.

In the manufacturing method having the above configuration, the design material forming step includes a bonding step in which the two separated design materials are pressed together to bond them together, and the bonding step and the separation step are repeated. can do.

In the method of manufacturing the board member having this configuration, it is possible to make the masses of the two design materials uniform by repeating the sticking process and the separating process.

In the manufacturing method having the above configuration, the design material forming step is performed after the separating step, and includes a brushing step in which the directions in which the first fibers and the second fibers extend are aligned in a specific direction. can do.

In the method for manufacturing a board member having this configuration, when the design material is adhered to the base material in the board member forming process performed later, the direction in which the fibers extend is aligned, so that the adhesive can be easily applied and the adhesion area can be increased. can be assured. In addition, in the case of irradiating light from the back side as described above to make the natural fibers of the fiber layer stand out on the surface of the film material, it is possible to match the direction of the fiber pattern of the film material. It is possible to ensure high designability in

In the manufacturing method having the above configuration, the design material molding step may be performed after the brushing step, and may include a pressing step for setting the thickness of the fiber layer to a predetermined thickness.

According to the method for manufacturing a board member having this configuration, the raised second fibers can be laid down, and the bonding area can be secured more reliably.

ADVANTAGE OF THE INVENTION According to this invention, in a board member, the unevenness|corrugation on the film by a natural fiber can be suppressed, and a fiber layer can be reliably adhere|attached with respect to a film material and a base material.

A view showing a vehicle using the board member of the present invention as viewed from inside the vehicle. FIG. 2 is a sectional view showing the ornament shown in FIG. 1 as seen from the rear side of the vehicle; 1 is an enlarged sectional view schematically showing a board member of the present invention; FIG. FIG. 2 is a plan view schematically showing a fiber layer that constitutes the board member of the present invention; Schematic showing the separation process Schematic diagram showing the brushing process Schematic diagram showing the pressing process Cross-sectional view schematically showing the completed design material A diagram schematically showing an image at the time of non-irradiation A diagram schematically showing an image at the time of irradiation

FIG. 1 shows a vehicle interior material that is an embodiment using the board member of the present invention. The vehicle interior material of the present embodiment is used for a door trim 12 that constitutes the interior surface of a side door 10 of a vehicle (automobile). The side door 10 is provided on the driver's seat side (the right side in the vehicle width direction) and the passenger's seat side (the left side in the vehicle width direction), respectively, and rotates about a rotation shaft extending generally in the vertical direction on the front side of the vehicle. , which can be opened and closed. Both the side door 10 on the side of the driver's seat and the door trim 12 of the side door 10 on the side of the driver's seat use the vehicle interior material of the present embodiment. In the following explanation, the door trim 12 of the side door 10 on the side of the driver's seat will be explained as a representative.

The door trim 12 constitutes the interior side portion of the side door 10, and is attached to the door inner panel from the interior side of the vehicle interior. The door trim 12 includes a lower board 14, an upper board 15, and an ornament 16, as shown in FIG. An armrest 17 is formed at the upper end of the lower board 14 , and the ornament 16 is arranged above the armrest 17 .

This ornament 16 is the vehicle interior material of the present embodiment. The ornament 16 is mainly composed of a housing 20 in which a space is formed. As shown in FIG. 1, the housing 20 has a longitudinal shape extending in the vehicle front-rear direction, and is fixed between the lower board 14 and the upper board 15 that constitute the door trim 12 so that one surface of the housing 20 faces the interior surface of the vehicle. constitutes part of

As shown in FIG. 2, the housing 20 has a generally box-like shape and is composed of a first housing member 21 forming a portion inside the passenger compartment and a second housing member 22 forming a portion outside the passenger compartment. Become. Specifically, the second housing member 22 has a bottom portion 23 (a portion on the outside of the passenger compartment) and a wall portion 24 standing from the periphery of the bottom portion 23, and is generally a dish-shaped member. there is On the other hand, the first housing member 21 is a lid-like member that closes the opening of the dish-shaped second housing member 22 . Specifically, the first housing member 21 has the same outer shape as the second housing member 22 when viewed in the vehicle interior and exterior directions, and is joined to the tip of the wall portion 24 of the second housing member 22 at its peripheral edge. ing.

A lighting device 30 is provided in the housing 20 . As shown in FIG. 2, the illumination device 30 includes a plurality of LED tapes 33 each having a longitudinal substrate 31 and a plurality of LEDs 32 arranged on the substrate 31 along the longitudinal direction. The LED tapes 33 are adhered to the bottom surface 23 of the second housing member 22 while being spaced apart in the vertical direction and extending in the longitudinal direction of the vehicle. The second housing member 22 is made of synthetic resin and does not transmit light or reflect light. The illumination device 30 can control the lighting state of the LED 32, specifically, can switch between lighting and extinguishing of the LED 32, and can change the illuminance within a certain range. It is possible to change the illuminance step by step from bright high illuminance to dark low illuminance.

The first housing member 21 is the board member of the present invention and consists of a skin material 40 and a base material 42 . The base material 42 is made of a highly translucent synthetic resin (for example, acrylic, polyethylene terephthalate, polycarbonate). In this embodiment, the base material 42 is made of acrylic. As shown in FIG. 2, the base member 42 has a chevron-shaped cross-section with the center in the vertical direction bulging toward the interior of the room. A skin material 40, which is a light-transmissive design material, is adhered to the indoor side surface of the base material 42. As shown in FIG.

As shown in FIG. 3, the skin material 40 is composed of a surface layer 44 forming a design surface and a fiber layer 46 adhered to the back surface of the surface layer 44 . The surface layer 44 is a film material mainly composed of a film substrate 50 made of a material having optical transparency. Although the film substrate 50 is not particularly limited, it is molded from polyvinyl chloride in this embodiment. The surface layer 44 includes a printed layer 52 in which a fiber pattern simulating the fiber layer 46 is formed by printing with inkjet paint on the surface side (inside the vehicle interior) of the film base material 50, and the surface side of the printed layer 52. Furthermore, a three-dimensional layer 54 formed of a resin material (for example, UV curable resin) having a light-transmitting uneven shape in accordance with the fiber pattern of the printed layer 52 is laminated. In this embodiment, the thickness of the surface layer 44 is about 130 μm to 230 μm. More specifically, the thickness of the film substrate 50 is about 70 μm to 90 μm, the thickness of the printed layer 52 is about 15 μm to 40 μm, and the thickness of the three-dimensional layer 54 is about 45 μm to 100 μm.

The fiber layer 46 is formed in a mat shape by intertwining vegetable fibers 60, which are natural fibers as first fibers, and resin fibers 62 as second fibers. Examples of the plant fibers 60 include bast plant fibers such as kenaf and wood fibers obtained by fibrillating wood or the like. Also, although plant fibers 60 are exemplified as natural fibers, animal fibers and mineral fibers may be used. In addition, in the fiber layer 46 of the present embodiment, the plant fibers 60, which are natural fibers, are kenaf fibers. The resin fiber 62 is made of a transparent or translucent resin material having optical transparency, and thermoplastic resins thereof include polyolefin resins (polypropylene, polyethylene, etc.), polyester resins (polylactic acid, polycaprolactone, etc.). aliphatic polyester resins, aromatic polyester resins such as polyethylene terephthalate), and the like. In addition, in this embodiment, the resin fiber 62 is made of polypropylene (PP).

In the present embodiment, the plant fibers 60, which are kenaf fibers, have an average fiber diameter of 80 μm or more and 100 μm or less, whereas the resin fibers 62 have a fiber diameter smaller than that of the plant fibers 60. ing. The fiber diameter of the resin fiber 62 is 10 μm or more and 30 μm or less. Further, as shown in FIG. 4, the plant fibers 60 are relatively linear fibers, while the resin fibers 62 are fibers having a crimped shape.

The fiber layer 46 is formed by mixing the plant fibers 60 and the resin fibers 62 at a predetermined ratio, opening the mixed material with a carding machine, and laminating the fibers. The fiber layer 46 is not subjected to needle punching, and holes and the like are not formed by the needle punching. Further, in the present embodiment, when the total mass of the mixed fiber obtained by mixing them is 100 wt%, the mixed fiber contains, for example, 70 wt% of the plant fiber 60 and 30 wt% of the resin fiber 62. can be Furthermore, in this embodiment, the fiber layer 46 is molded so that the mass per unit area is about 10 g/m ² . Although the fiber layer 46 will be described in detail later, the fiber layer 46 is for expressing the image of natural fibers on the design surface of the first housing member 21, so the mass per unit area of the fiber layer 46 is relatively small. , 8 g/m ² or more and 20 g/m ² or less. Furthermore, it is more desirable to be 8 g/m ² or more and 12 g/m ² or less.

Incidentally, if the fiber layer 46 is made of only the plant fibers 60, the resin fibers 62 are unnecessary from the viewpoint of expressing the texture of the fibers on the design surface of the first housing member 21. FIG. On the other hand, when the fiber layer 46 is composed only of the plant fibers 60, the film substrate 50 is the main component, and the thickness is relatively thin. , there is a problem that unnatural unevenness is generated due to natural fibers, and the feeling of natural fibers is spoiled. In addition, since the surface of the fiber layer 46 has non-uniform natural fibers in order to express the feeling of natural fibers, the adhesion of the fiber layer 46 to the base material 42 or the surface layer 44 is uneven (i.e., uneven adhesion on the bonding surface). There was a problem that the adhesive force variation) occurred.

In the present embodiment, as described above, the fiber layer 46 is mainly made of the vegetable fibers 60 and is made by intertwining the resin fibers 62 having a smaller fiber diameter than the vegetable fibers 60. By interposing the plant fibers 62 between the surface layer 44 and between the plant fibers 60 and the base material 42 , it is possible to suppress unevenness caused by the plant fibers 60 on the surface layer 44 . Moreover, the presence of the resin fibers 62 increases the surface area of the fiber layer 46, that is, increases the bonding area. In addition, since the resin fibers 62 are dispersed even in areas where there are few plant fibers 60, it is possible to suppress variations in adhesive strength on the adhesive surface. Therefore, in this embodiment, the fiber layer 46 can be reliably adhered to the surface layer 44 and the base material 42 . In addition, in order to increase the adhesive force while expressing the fiber feeling, for example, the content of the vegetable fiber 60 is 50 wt% or more and 80 wt% or less, and the total mass of the plant fiber 60 is 100 wt%. It is desirable that the resin fiber 62 is contained at a rate of 50 wt % or less and 20 wt % or more. More preferably, the content of the plant fiber 60 is 65 wt % or more and 75 wt % or less, and the resin fiber 62 is contained at a rate of 35 wt % or less and 25 wt % or more.

Here, a method for manufacturing the first housing member 21, which is the board member of this embodiment, will be described. First, the plant fibers 60 and the resin fibers 62 are mixed at the above-described predetermined ratio. By opening and laminating the mixed fibers by a carding machine, a planar fiber web 70 as shown in FIG. 5 is formed (fiber web forming step). However, the fibrous web 70 is formed so as to have a basis weight more than twice the target basis weight of the fiber layer 46 .

Next, two sheets of film material 72 corresponding to the surface layer 44 are prepared. These two film materials 72A and 72B are attached to each of the two surfaces of the fiber web 70 (film material adhering step). By the way, an adhesive is laminated on the back surface of the film material 72 , more specifically, on the back surface of the film base material 50 , so that it can be adhered to the fiber web 70 by the adhesive. In this case, since the fiber web 70 is configured such that the resin fibers 62 having a small fiber diameter are present around the plant fibers 60, the film materials 72A and 72B can be firmly adhered.

Subsequently, as shown in FIG. 5, the upper film material 72A is separated from the lower film material 72B so as to be separated into two (separation step). In the fiber web 70 , the resin fibers 62 having a small fiber diameter are entangled with the plant fibers 60 , and the resin fibers 62 tend to extend outward from the plant fibers 60 . That is, the film materials 72A and 72B are likely to have the resin fibers 62 attached thereto. When the fiber web 70 is separated from this state, the fiber webs 70A and 70B bonded to the respective film materials 72A and 72B are in such a state that the resin fibers 62 having a small fiber diameter are particularly pulled toward the other, and the film It stands up against the material 72 and tends to become fuzzy. As a result, a portion of the resin fibers 62 extends to the side opposite to the film material 72 with respect to the plant fibers 60 . That is, when the design material 74 composed of the film materials 72A, 72B and the fiber webs 70A, 70B is adhered to the base material 42, the standing resin fibers 62 can reliably secure the adhesion area.

In addition, in the present embodiment, after the separation step, the separated two design materials 74 are bonded together by pressing the surfaces of the fiber webs 70A and 70B together (bonding). process). Then, this adhering process and the above-described separating process are repeatedly performed, so that the masses of the two design materials 74 are made uniform.

Next, as shown in FIG. 6, fiber webs 70A and 70B are brushed in a specific direction for each design material 74. Then, as shown in FIG. By this brushing process, the directions in which the fibers of the fiber webs 70A and 70B extend are aligned in a specific direction. Furthermore, in this brushing process, the basis weight of the fiber webs 70A and 70B is set to be the target basis weight. The fiber webs 70A and 70B in the design material 74 tend to have the resin fibers 62 adhered to the film material 72, and the plant fibers 60 tend to be held by the resin fibers 62, as described above. Therefore, in the brushing process, the presence of the resin fibers 62 facilitates brushing the plant fibers 60 in a specific direction.

Incidentally, the brush 80 used in this brushing process has elastic fibers and a spherical tip. As a result, the directions of the fibers can be effectively aligned while preventing the film material 72 from being damaged. The brush 80 has a mixture of long fibers and short fibers in order to brush the vegetable fibers 60 having a large fiber diameter and brush the resin fibers 62 extending to the opposite side of the film material 72 . is desirable.

Further, after this brushing process, as shown in FIG. 7, a pressing process is performed by rollers 82 to set the thickness of the fiber webs 70A and 70B to a predetermined thickness. As a result, the standing resin fibers 62 are laid down while aligned in a specific direction. As a result, as shown in FIG. 8, the skin material 40, which is a light-transmitting design material, is completed. Since the skin material 40 is in a state in which the resin fibers 62 are aligned in a specific direction and laid by the brushing process and the pressing process, it is easy to apply the adhesive onto the fiber webs 70A and 70B. In addition, the adhesion area to the base material 42 can be reliably secured. In the film material 72 described above, the fiber pattern of the printed layer 52 imitates the above-described brushed plant fiber 60, and is a fiber pattern extending in a specific direction. As described above, the design material molding process for molding the design material 74 includes the above-described separating process, adhering process, brushing process, and pressing process.

Then, an adhesive is applied to the fiber webs 70A and 70B of the skin material 40, and the fiber webs 70A and 70B are attached to the base material 42, thereby completing the first housing member 21, which is the board member of the present invention. molding process). The fiber webs 70A and 70B of the skin material 40 are not bound by the thermoplastic resin, and the shape can be changed relatively freely. However, it can be glued along its shape. In addition, with this configuration, the skin material 40 can be attached to various shapes, and board members of various shapes can be realized. In addition, since the fiber webs 70A and 70B have the resin fibers 62, the liquid adhesive can be firmly held when the fiber webs are formed only from the plant fibers 60, so that the bonding to the base material 42 is improved. It can be done with certainty. Furthermore, even when the upholstery material 40 is adhered to a standing wall-like portion, the adhesive is less likely to drip downward and can be firmly adhered.

The first housing member 21, which is a board member configured as described above, has a fiber pattern provided on the surface layer 44 as shown in FIG. expresses the feeling of natural fibers. On the other hand, when the illumination device 30 is turned on and light is emitted from the back side, the fiber pattern provided on the surface layer 44 is partially blurred or disappears due to the light. However, as shown in FIG. 10, the vegetable fibers 60 in the fiber layer 46 stand out on the surface of the surface layer 44, and the feeling of natural fibers can be expressed. When the illumination device 30 is turned on, the direction in which the fiber pattern of the surface layer 44 extends and the direction in which the plant fibers 60 of the fiber layer 46 protruding from the surface layer 44 extend are the same. It does not cause , and secures high designability.

<Other embodiments>
The present invention is not limited to the above embodiments, and can be implemented in various aspects with various modifications and improvements based on the knowledge of those skilled in the art. For example, the following embodiments are also included in the technical scope of the present invention.

In the above embodiment, the fiber layer 46 is mixed with the resin fibers 62 as the second fibers, but is not limited thereto, and natural fibers having a smaller fiber diameter than the vegetable fibers 60 as the first fibers ( For example, cotton) can also be used. According to this aspect, when lighting device 30 is lit, a sense of depth can be expressed by using two types of natural fibers having different fiber diameters. Furthermore, when the mixed fibers are spread and laminated, the surface layer 44 side has a mat shape in which the first fibers (kenaf fibers) 60 having a large fiber diameter are larger than the second fibers (cotton). By molding, it is possible to create a greater sense of depth. Moreover, three or more types of fibers to be mixed, for example, fibers having different fiber diameters may be mixed to form a fiber layer.

Moreover, the fiber layer can be formed by mixing two or more kinds of natural fibers having the same color but different shades. According to this aspect, it is possible to express a sense of depth by using two types of natural fibers with different shades. Furthermore, when the mixed fibers are opened and laminated, the surface layer 44 side is formed into a mat shape in which the darker-colored natural fibers are more abundant than the lighter-colored natural fibers. can issue

In the above embodiment, the board member is used for the vehicle door trim 12, but it is not limited thereto, and can be used for other vehicle interior materials such as a vehicle ceiling material and an instrument panel. Moreover, it is not limited to vehicles, and can be used as an interior material for other vehicles. Furthermore, it is not limited to interior materials for vehicles, and can be used for interior materials of buildings, furniture, and the like.

DESCRIPTION OF SYMBOLS 16... Ornament [vehicle interior material], 21... First housing member [board member], 30... Lighting device, 40... Skin material [design material], 42... Base material, 44... Surface layer, 46... Fiber layer, 50 Film substrate 52 Printed layer 54 Three-dimensional layer 60 Plant fiber [natural fiber, first fiber] 62 Resin fiber [second fiber] 70, 70A, 70B Fiber web 72A, 72B... Film material, 74... Design material

Claims (11)

a plate-like substrate;
a fiber layer composed mainly of natural fibers and adhered to the surface side of the substrate;
a film material that is adhered to the surface side of the fiber layer and forms a design surface,
The board member, wherein the fiber layer is formed by intertwining first fibers, which are natural fibers, and second fibers, which are fibers thinner than the fiber diameter of the natural fibers, to form a mat. The board member according to claim 1, wherein the first fibers have a fiber diameter of 80 µm or more and 100 µm or less, and the second fibers have a fiber diameter of 10 µm or more and 30 µm or less. The board member according to claim 1 or 2, wherein the fiber layer has a mass per unit area of 8 g/m2 ^or more and 20 g/ ^m2 or less. The board member according to any one of claims 1 to 3, wherein the content of the second fibers in the fiber layer is 20% or more and 50% or less. The film material is made of a material having optical transparency, and has a fiber pattern printed on the surface,
5. The board member according to any one of claims 1 to 4, wherein the base material is made of a light-transmitting material. 6. The board member according to claim 5, wherein the second fibers are resin fibers having optical transparency. The fiber layer is formed so that the first fibers extend in a specific direction,
7. The board member according to claim 5, wherein the fiber pattern of the film material is a pattern extending in the specific direction. A manufacturing method for manufacturing the board member according to any one of claims 1 to 7,
a fibrous web forming step of forming a fibrous web with the first fibers and the second fibers in an amount that is at least twice the target mass per unit area in the fibrous layer;
a film material adhering step of adhering the two film materials to both surfaces of the fiber web;
A design material forming step of forming two pieces of design material in which the fiber layer is laminated on the film material, including a separation step of separating one of the two film materials from the other by peeling it off;
A board member forming step of forming the board member by bonding the design material to the surface of the base material;
A method for manufacturing a board member having 9. The design material forming step includes an adhering step in which the two separated design materials are pressed together to bond them together, and the adhering step and the separating step are repeated. A method of manufacturing the described board member. 10. The design material forming step according to claim 8 or 9, wherein the design material forming step is performed after the separating step, and includes a brushing step in which the directions in which the first fibers and the second fibers extend are aligned in a specific direction. A method for manufacturing a board member of 11. The method of manufacturing a board member according to claim 10, wherein the design material forming step includes a pressing step that is performed after the brushing step and sets the thickness of the fiber layer to a predetermined thickness.

Images