JPS63249752A - Production of fiber molded body - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

Detailed Description of the Invention (Field of Industrial Application) The present invention provides a molded article that is lightweight and has excellent heat resistance, moldability, sound absorption, rigidity, and cushioning properties, and a fiber molded article that is particularly useful as a ceiling material for automobiles. Concerning a method of manufacturing a body.

(Prior Art) Cardboard and various resin foams have traditionally been used for molded ceilings, which are one of the interior materials of automobiles. Among these, cardboard has the advantage of being lightweight and inexpensive, but it has poor shaping properties because the only means of shaping is compression, and it cannot be shaped into delicate shapes, and it is hygroscopic. However, it has the disadvantage of poor shape retention. Therefore, resin foam is now more widely used for molded ceilings than cardboard, which has these drawbacks.

Examples of molded ceilings using resin foam include molded ceilings using modified polystyrene foam, such as those found in Japanese Patent Application Laid-open No. 58-71154 and Japanese Patent Publication No. 58-2811. Such a molded body is obtained by foaming resin and molding it into a desired shape, so it has excellent shapeability, and the molded body obtained is relatively strong and lightweight.
Excellent insulation, heat resistance, and elasticity (cushioning properties).

Also, JP-A-55-11947 and JP-A-53-1
As seen in Publication No. 4074 or Japanese Patent Publication No. 57-60944, there are cases in which the molded ceiling is further laminated with reinforcing material to improve its rigidity, sound absorbing material is laminated, or through holes are formed in the base material. Some devices aim to improve the sound absorption effect by providing a.

(Problem to be solved by the invention) However, since the former molded ceiling uses thermoplastic resin, it is inferior in dimensional stability and rigidity at high temperatures, and it is difficult to obtain a heat insulation effect. Since closed-cell foam is used, there is a problem in that sound is reflected on the surface and a sufficient sound absorption effect cannot be obtained.

On the other hand, although the latter type of molded ceiling does not have the problems of the former, it does have the problem of complicating the manufacturing process and increasing costs. Furthermore, since the weight of the molded ceiling itself increases, there is a problem in that the fuel consumption of the automobile decreases.

The present invention aims to solve the above-mentioned conventional problems, and is lightweight, has rigidity, has good moldability, heat resistance,
It is an object of the present invention to provide a method for manufacturing a molded body suitable for a molded ceiling of an automobile, which has excellent heat insulation, sound absorption, and cushioning properties, and also has excellent rigidity and dimensional stability at high temperatures.

(Means for Solving the Problems) The method for producing a fiber molded body according to the present invention is to produce a fiber molded body on a sheet material made of an organic substance, or on a sheet-like molded body in which inorganic fibers as the main constituent material are mutually bonded with an organic substance. After laminating a blended fabric consisting of inorganic fibers and organic fibers, a large number of felt needles are passed through the sheet material or the sheet-shaped molded body from the blended fabric side, and a part of the blended fabric is inserted into the sheet material or sheet-shaped molded body. The intermediate product is made to protrude to the back side, and then the intermediate product is heated to a temperature higher than the melting point of the organic substance and the organic fibers to melt the organic substance and the organic fibers, and then it is shaped into a predetermined shape. It is characterized by being compressed and molded.

Furthermore, the present invention will be explained in detail.

First, a sheet material made of a thermoplastic resin such as polyethylene, polypropylene, polystyrene, unsaturated polyester, or polyvinyl butyral is manufactured in advance by, for example, extrusion.

Alternatively, for example, by dispersing inorganic fibers such as glass fibers or rock wool together with the thermoplastic resin powder or fibers, and heating and compressing the inorganic fibers, the inorganic fibers are used as the main constituent material, and the inorganic fibers are formed by the resin. A sheet-like molded body is manufactured by adhering these to each other. The thickness of these sheet materials or sheet-like molded bodies is preferably in the range of 0.05 to 0.41 mm in order to maintain the strength of the molded bodies. This is because if the thickness is thinner than this, the strength will be insufficient, and if it is thicker, the molded product will be heavy.

Next, blended products (fibers made into cotton by opening and mixing them)
A machine generally called a card machine is used to produce a blend of inorganic fibers and organic fibers, and this is laminated on the sheet material or sheet-like molded product as described above. The inorganic fibers of this blend can be glass fibers, rock wool, etc. as described above,
The above-mentioned thermoplastic resin can also be used as the organic fiber. The ratio of these inorganic fibers to organic fibers is 1 by weight.
0=1 to 1:5 is preferable. If the amount of organic fibers is too small, the adhesive effect of the organic fibers will be insufficient as will be explained later, and the molded product will be weak. Also, even if there is too much organic fiber,
As will be explained later, there is too little inorganic fiber, which is the main component of the molded product, and the strength is also insufficient.

Once the blended fabric is laminated on the sheet material or sheet-like molded body as described above, a large number of felt needles are passed from the blended fabric side to the opposite side (
By penetrating to the back side), some fibers of the blended fabric are made to protrude to the back side of the sheet material or sheet-like molded body. Here, the felt needle has a large number of protruding points on its tip and side surfaces for hooking fibers, and commonly available felt needles can be used. Through this process, the fibers of the blend are intertwined with each other using felt needles and formed into a nonwoven fabric with a strength that does not hinder handling, and then joined with the sheet material or sheet-like molded body to produce an intermediate product of the integrally molded body. Nasu.

Subsequently, this intermediate integrally molded product is heated to a temperature higher than the melting point of the organic substance and the organic fibers to melt the organic substance and the organic fibers, and then compressed into a predetermined shape to obtain the desired fiber molded body. .

By the above method, the desired fiber molded body can be manufactured.

Note that the sheet material layer or the sheet-like molded layer is preferably used on the back side of the ceiling of the automobile (the side opposite to the passenger compartment) from the viewpoint of sound absorption, but since there are many holes made with felt needles, Even if it is used on the passenger compartment side, the sound absorption properties are only slightly reduced and there is no particular problem. In some cases, this layer is placed on the passenger compartment side, and a reinforcing layer or an air barrier layer is provided on the opposite side.

(Function) In the nonwoven fabric layer of the blended material in the molded product, the organic fibers are heated to a temperature higher than the melting point, melt and form droplets, and when pressurized and molded, they adhere to the intersections of the inorganic fibers, and the adhesive Work as. This results in a three-dimensional network structure mainly composed of inorganic fibers. Therefore, it has good moldability and is heat resistant (dimensional stability at high temperatures) because it has inorganic fiber as its main skeleton.
Because it has a three-dimensional network structure, it has excellent heat insulation, sound absorption, and cushioning properties, and is lightweight. Furthermore, the sheet material layer made of an organic material that is in close contact with one side or the sheet-like molded body layer made of inorganic fibers bonded with an organic material has good moldability because it is heated above the melting point of the organic material and compression molded. In addition, since it acts as a reinforcing layer for the molded body having the three-dimensional network structure, the strength of the molded body as a whole becomes excellent.

(Effects of the Invention) As described above, according to the method for manufacturing a fiber molded article of the present invention, it is lightweight and rigid, and has excellent moldability, heat resistance (dimensional stability at high temperatures), heat insulation, sound absorption and It is possible to produce a fiber molded body that has extremely excellent cushioning properties and is suitable for molded ceilings of automobiles.

(Example) Examples of the present invention will be shown below, but the present invention is not limited thereto.

<Example 1> As a sheet material, the thickness is about 0.211, the weight is about 200 g/
,, using styrene sheets of f, and as a blended material,
A blend of glass fiber and polyethylene fiber at a weight ratio of 1:2 and a weight of 500 g/= was used.

The blended fabric was laminated on the sheet material as described above, and felt needles were pierced and penetrated at a rate of approximately 2 felt needles/d to integrate the fabric.

Place this integrated product in an oven at 200℃, heat it for 2 minutes, take it out, and make it into a single plate with a thickness of 5+n with one end rounded.
It was pressed into a shape (see drawing) having a deep drawing part of 5+u. The press pressure at this time is 0.5kg/c++l
I made it.

Then, the molded body was taken out, the moldability of the deep-drawn portion 2 was observed, and the strength, sound absorption, and heat resistance (dimensional change at 90° C.) of the veneer portion 1 were measured. The results are shown in the table.

<Example 2> As a sheet material, glass fiber and polyethylene fiber were mixed at a weight ratio of 1:2, heated to 200°C, and 1 kg /
A sheet formed by compressing with a pressure of crA was used.

The thickness of this sheet material is approximately 0.2 fs, and the weight is approximately 200 fs.
g/m.

The same blend as in Example 1 was used, and a molded product was obtained in the same manner as in Example 1.

The same measurements as in Example 1 were performed on the obtained molded body. The results are shown in the table.

<Comparative Example 1> The same sheet material and blended fabric as in Example 1 were used, but
No penetration was made with a felting needle.

Other steps were performed in the same manner as in Example 1.

Then, the same measurements as in Example 1 were performed on the obtained molded body. The results are shown in the table.

Comparative Example 2> The same sheet material and blended fabric as in Example 2 were used, but
No penetration was made with a felting needle.

Other steps are the same as in Example 1.

Then, the same measurements as in Example 1 were performed on the obtained molded body. The results are shown in the table.

<Comparative Example 3) Comparative Example 1.2 above using only a blended material without using any sheet material
A molded body was obtained in the same process as above. In addition, as a blended fabric,
A blend of glass fiber and polyethylene fiber at a weight ratio of 1:2 and a weight of 500 g/rd was used.

Then, the same measurements as in Example 1 were performed on the obtained molded body. The results are shown in the table.

Comparative Examples 4 to 6 Regarding three types of closed-cell foams conventionally used as automobile ceiling materials: styrene foam (4), polyethylene foam (5), and a laminate of polyethylene foam and cardboard (6) The same measurements as in Example 1 were also carried out. The results are shown in the table.

As is clear from the above results, according to the present invention, a fiber molded article that is extremely excellent in all aspects of moldability, strength, sound absorption, and heat resistance can be obtained.

[Brief explanation of drawings]

The drawings are diagrams showing the shape of molded bodies used in Examples. 1...Single plate part 2...Deep drawing part Patent applicant
Sekisui Chemical Co., Ltd. Representative Hiroshi 1) Kaoru

Claims (1)

[Claims] 1) After laminating a blended fabric made of inorganic fibers and organic fibers on a sheet material made of an organic substance or a sheet-like molded body in which inorganic fibers as the main constituent materials are mutually bonded with an organic substance, a large number of fibers are laminated from the side of the blended fabric. A felt needle is passed through the sheet material or the sheet-like molded product to make a part of the blend protrude to the back side of the sheet material or the sheet-like molded product to form an intermediate integrally molded product, and then this integrally molded intermediate product is made. A method for producing a fiber molded article, which comprises heating the article to a temperature equal to or higher than the melting point of the organic substance and the organic fibers to melt the organic substance and the organic fibers, and then compressing and molding the article into a predetermined shape.