JPH06257051A - Fiber composite material - Google Patents

Abstract

PURPOSE:To enable lightening and improve flame resistance and heat resistance. CONSTITUTION:This fiber composite material is composed of a mixture of many glass fibers and many cotton fibers partly bonded to each other by polyethylene and the mixing ratio of both the fibers is 6:4 on weight base. This fiber composite material contains many voids over the whole body and the average void content is 86%.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a fiber composite used as an interior material for automobiles such as a ceiling core material or a door core material for automobiles and an interior material for construction.

[0002]

2. Description of the Related Art In general, the above interior materials are required to be lightweight and have excellent properties such as rigidity, combustion resistance, heat resistance, sound absorption, and moldability. Conventionally, as this kind of material,
(A) A fiber composite in which a large number of inorganic fibers are partially bonded to each other with a thermoplastic resin and have a large number of voids throughout (see JP-A-1-156562),
(B) A fiber composite (see JP-A-1-174661) in which a large number of plant fibers are partially bonded to each other with a thermoplastic resin and have a large number of voids throughout, and (C) a large number of syntheses. A fiber composite is known in which fibers are partially bonded to each other by a thermoplastic resin and have a large number of voids throughout (see JP-A-1-165431).

[0003]

Although the composite of the above (a) is lightened due to a large number of voids, it is heavy due to the use of inorganic fibers, and further weight reduction is demanded. In addition, since the composite fiber of the above (b) uses plant fiber in all, it has a problem in combustion resistance. Furthermore, since the composite of (c) above uses inorganic fibers and synthetic fibers, when deep drawing is performed, the synthetic fibers of both fibers are in a stretched state, and as a result, molding is performed at high temperatures. It transforms when the item is used. Therefore, the kind of synthetic fiber must be selected in consideration of the heat resistance required temperature.

An object of the present invention is to solve all the above problems and to provide a fiber composite which can satisfy all the above-mentioned performances required for interior materials for automobiles.

[0005]

The fiber composite according to the present invention has a large number of inorganic fibers and a large number of plant fibers mixed together in a partially bonded state with a thermoplastic resin and has a large number of voids throughout. The average porosity is 65 to 95%. In the above, the reason why the average porosity of the fiber composite is set to 65 to 95% is that if it is less than 65%, the lightness is not sufficient, and if it exceeds 95%, the strength becomes poor. Specific examples of the inorganic fiber include glass fiber, rock wool, ceramic fiber, carbon fiber and the like, and the length thereof is preferably 5 to 200 mm from the viewpoint of moldability of the mat-like material described later, and its thickness is If it is thin, the mechanical strength is lowered, and if it is thick, it tends to be broken during mat molding, so that it is preferably 5 to 30 μm, more preferably 9 to 17 μm. If the diameter ratio of the inorganic fibers to the plant fibers exceeds 1: 5, the defibration and mixing of fibers in the card machine described later will be poor. It is necessary to select the diameter of the inorganic fiber.

Specific examples of the vegetable fiber include cotton, flax and jute, which may be used alone or in combination. For cotton, the natural length may be 10 to 60 mm, and for flax, the natural length may be 10 to 100 mm, or the longer one may be cut in half. 10 for jute with a natural length of 10 to 200 mm
Those having a diameter of 0 mm or less are used as they are, and those having a diameter exceeding this value are cut to be at least 100 mm and used.

[0007] The diameter of the plant fiber varies because it is a natural product, but in general, cotton is 12 to 38 µm and flax is 20 to 38 µm.
25 μm, jute is 15 to 30 μm. Diameter is 40
Those having a thickness of about 60 μm are not suitable for use because they are too thick and are likely to cause uneven weight when obtaining a fiber composite with other fibers.

Examples of the thermoplastic resin include polyeletin, polypropylene, saturated polyester, polyamide, vinyl chloride, polystyrene and the like. And
When the fiber composite is obtained from the mat-like material described later, it is necessary to laminate it on both sides thereof as films. The thickness of this film can be appropriately determined by the ratio of the inorganic fibers and the plant fibers constituting the mat-like material.

The method for producing the mat-like material for obtaining the fiber composite is arbitrary. For example, first, inorganic fibers and plant fibers are fed to a card machine, defibrated and mixed, and then needle punched. A method of obtaining a mat-like material by treatment is mentioned. The needle punch density at this time is
50 to 100 per cm ² is preferable. The fibers are entangled by the needle punching process.

Thermoplastic resin films are laminated on both surfaces of the mat-like material, and the laminate is heated and compressed to impregnate the mat-like material with the molten thermoplastic resin, and then decompressed, and the impregnated resin is in a molten state. Inside, the laminate is pulled in the thickness direction and inflated to obtain a fiber composite. In the production of the mat-like material, thermoplastic organic fibers such as polyethylene, polypropylene, saturated polyester, polyamide, and polyacrylonitrile may be added to join the fibers to each other and to increase the bulk of the mat-like material. .

The weight ratio of the inorganic fiber to the plant fiber is not unequivocally stated because the ratio of the thermoplastic resin is also involved.
It is preferably 3: 7 to 7: 3. If the amount of vegetable fiber is too large, the flame resistance becomes poor, and if it is too small, it becomes difficult to reduce the weight.

The weight ratio of fiber to thermoplastic resin is from 2: 8 to.
6: 4 is preferable. If there are too few or too many fibers, the strength will be poor.

[0013]

In the fiber composite according to the present invention, a large number of inorganic fibers and a large number of plant fibers are mixed and partially bonded with a thermoplastic resin and have a large number of voids throughout, and the average porosity is 65. Since it is ~ 95%, the weight is further reduced as compared with the fiber composite in which only the inorganic fiber is used, and the combustion resistance is excellent as compared with the fiber composite in which only the plant fiber is used. There is no problem of thermal deformation as in the deep-drawing products made of fiber composites with inorganic and synthetic fibers.

[0014]

EXAMPLES Examples of the present invention will be described below.

Example 1 The fiber composite of this example has a length of 50 mm and a diameter of 9 μm.
Glass fiber and length 10-60mm, diameter 12-38μ
The cotton fibers of m are partially joined with polyethylene in a mixed state of a weight ratio of 6: 4 and have a large number of voids throughout, and the average void ratio is 86%. In addition,
The weight ratio of fiber to polyethylene (including melted polyethylene fiber described later) is 3: 4.

The above fiber composite is manufactured as follows. That is, length 50 mm, diameter 9
Glass fiber of μm, length 10 to 60 mm, diameter 12 to
38 μm cotton fiber and 50 mm long, 30 μm diameter polyethylene fiber were supplied to the card machine at a weight ratio of 6: 4: 5, and after being defibrated, needle punching was performed at 80 points per 1 cm ² to obtain a thickness of 7 mm and a width. A mat-like material having a length of 1 m, a length of 1 m and an average weight of 450 g / m ² was obtained.

A high density polyethylene film having a thickness of 130 μm and a weight of 125 g / m ² was laminated on both surfaces of the mat-like material, and the obtained laminate was sandwiched between polytetrafluoroethylene films having a thickness of 250 μm at 200 ° C. After heating for 3 minutes, press at 200 ° C to press 5 kg / c
While compressing at a pressure of m ² and maintaining the temperature at 200 ° C., the polytetrafluoroethylene films on both sides are vacuum-sucked in the thickness direction at a speed of 1 mm / sec, and the laminate is inflated to a thickness of 4 mm and then cooled. Then, the polytetrafluoroethylene film was peeled off from the laminate to obtain a fiber composite.

Example 2 In this example, the weight ratio of glass fiber to cotton fiber was 4: 6,
Same as Example 1 except that the weight ratio of fiber to polyethylene is 3: 4 and the average porosity is 85%.

Example 3 This example shows that instead of cotton fiber, the length is 10 to 50 mm,
The same as Example 1 except that flax fibers having a diameter of 20 to 25 μm were used and the average porosity was 86%.

Example 4 This example shows that instead of cotton fiber, the length is 10 to 50 mm,
Same as Example 1 except that jute fibers having a diameter of 15 to 30 μm were used and the average porosity was 86%.

Comparative Example 1 This comparative example is the same as Example 1 except that glass fiber is not used, the weight ratio of cotton fiber to polyethylene is 3: 4, and the average porosity is 84%.

Comparative Example 2 This comparative example is the same as Example 1 except that cotton fiber is not used, the weight ratio of glass fiber to polyethylene is 3: 4, and the average porosity is 86%.

Comparative Example 3 This comparative example is the same as Example 1 except that glass fiber was not used, the weight ratio of flax fiber to polyethylene was 3: 4, and the average porosity was 84%.

Comparative Example 4 This comparative example is the same as Example 1 except that glass fiber was not used, the weight ratio of jute fiber to polyethylene was 3: 4, and the average porosity was 84%.

Comparative Example 5 In this comparative example, a glass fiber having a length of 50 mm and a diameter of 10 μm and a polyester fiber having a length of 50 mm and a diameter of 10 μm (2 denier) were used at a weight ratio of 6: 4, and the weight of the fiber and the polyethylene was set. Same as Example 1 except the ratio is 3: 4 and the average porosity is 85%.

The fiber composites of Examples and Comparative Examples were made to have a width of 5
Cut to 0 mm and length 150 mm, JIS K-722
A bending test was performed according to 1. In addition, the fibrous composites having a width of 50 mm in each example and each comparative example were burned from one end, the time for burning 250 mm was measured, and the average speed (cm / min) was obtained. Repeat this 10 times to measure,
Indicates the maximum value. When used as a ceiling material for automobiles, it must be a quasi-incombustible grade of 10 cm / min or less.

Further, the fiber composites having a width of 50 mm and a length of 400 mm in each example and each comparative example were heated to 170 ° C. and press-formed into an inverted L shape shown in FIG. This was left at 105 ° C. for 100 hours, and the deformation σ (return) of the terminal was measured. In FIG. 1, (1) is a base, (2) is a fiber composite molded into an inverted L shape, the solid line shows before deformation, and the chain line shows after deformation.

The above measurement results are summarized in Table 1.

[0029]

[Table 1] As is clear from Table 1, according to the present invention, it is possible to reduce the weight as compared with the case of using only the inorganic fiber (Examples 1 to 3 vs. Comparative Example 2), and the combustion resistance as compared with the case of using only the plant fiber. Is improved (Examples 1 and 2 vs. Comparative Example 1. Examples 3 and 4 vs. Comparative Examples 3 and 4), and the heat resistance is the same as when only glass fiber is used, compared with the case where synthetic fiber is used. Improved (Examples 1 to 4 vs. Comparative Examples 2 and 5).

[0030]

According to the fiber composite of the present invention, the weight is further reduced as compared with the fiber composite in which only the inorganic fiber is used, and in comparison with the fiber composite in which only the plant fiber is used. It is excellent in combustion resistance, and because it does not have the problem of thermal deformation unlike the deep-drawing molded product made of a fiber composite that uses inorganic fibers and synthetic fibers, it is lightweight, and has rigidity, combustion resistance, heat resistance, and sound absorption. It is suitable for interior materials for automobiles and interior materials for construction, which require materials having excellent performance such as moldability.

[Brief description of drawings]

FIG. 1 is a vertical sectional view of a molded fiber composite in a heat distortion test.

[Explanation of symbols]

 1: Stand 2: Fiber composite

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁵ Identification code Office reference number FI technical display area // B60R 13/02 Z

Claims (1)

[Claims] 1. A large number of inorganic fibers and a large number of plant fibers are partially joined by a thermoplastic resin in a mixed state and have a large number of voids throughout, and the average porosity is 65 to 95.
%, A fiber composite.