JPH0994887A - Three-dimensional coconut husk long fiber structure mat reinforced resin molded object, laminate thereof, production thereof and use thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To more enhance characteristics such as strength, rigidity or peel strength three-dimensionally by using a three-dimensional coconut husk long fiber structure mat obtained by bonding and fixing fibers using a binder as a reinforcing material. SOLUTION: A plurality of three-dimensional long coconut husk long fiber structure mats (c) or three-dimensional long coconut husk long fiber structure mats (d) are laminated. The laminated three-dimensional coconut husk long fiber structure mat is impregnated with a resin to produce a three-dimensional coconut husk long fiber structure mat reinforced resin molded object. When the mats are laminated, if necessary, in order to reinforce the interlaminar parts of the lamainate three-dimensional coconut husk long fiber structure mats, the laminated mat is subjected to needle punching. A large number of coconut hust long fiber 11 are arranged between the mats in lateral and longitudinal directions so as to leave intervals. The mats laminated by a stitch bond method in place of a needle punching method are sewn so as to leave gaps in lateral and longitudinal directions.

Description

Detailed Description of the Invention

[0001]

TECHNICAL FIELD The present invention relates to a three-dimensional palm shell long-fiber structure mat-reinforced resin molded product, a laminate thereof, a method for producing the same, and uses thereof, and more specifically,
Lightweight, three-dimensional palm shell long fiber structure mat reinforced resin molded product with excellent peel strength, strength, rigidity, impact resistance, sound absorption, cushioning, heat insulation, sawing, nailing, etc., A laminated body in which a layer made of an organic material or an inorganic material is laminated on the reinforced resin molded body as a base material, and a manufacturing method for easily manufacturing these using palm shell fibers, and a ceiling material using these The present invention relates to a material using palm shell filaments that can be used for wall materials, floor materials, furniture, tatami floors, packing materials, pallet materials, etc.

[0002]

2. Description of the Related Art Conventionally, fibers of palm plants have been effectively used alone as fishnets, ropes, brooms, scrubbers, rugs, etc., or in combination with plastics, rubber, wood, etc.
Synthetic wood (JP-A-50-60545), building wall material (JP-A-51-39780), sound insulation material (JP-A-53-84315), cushion material, etc. (JP-A-54) -55082), insole material for shoes (JP-A-54-68352), oil-containing wastewater treatment material (JP-A-55-104381), core of automobile inner panel (JP-B-54-20993). ), Mat for bedding (Japanese Patent Application Laid-Open No. 59-164087), indoor wall (Japanese Patent Application Laid-Open No. 2-212344), packing, and construction materials (Japanese Patent Application Laid-Open Nos. 5-177771 and 7-1096).
52), tatami floor (Japanese Patent Application No. 4-68077)
It is proposed to use it for many purposes.

However, conventionally, the properties such as the strength of the fibers of the palm plant have not been effectively utilized, and the strength of the fibers in one direction can be utilized or the strength of the fibers in a two-dimensional direction can be obtained by arranging the fibers in a plane. Many of them are used, and when the strength in the three-dimensional direction is used, the fibers are randomly arranged in the three-dimensional, so that the strength, rigidity, peeling strength, etc. are three-dimensional in any direction. There was a drawback that large products could not be obtained.

[0004]

SUMMARY OF THE INVENTION The present invention has been made in order to sufficiently effectively utilize the properties such as the strength of coconut shell fiber, and is lightweight, and three-dimensionally has a peeling strength in any direction. Provides a three-dimensional palm long fiber structure mat reinforced resin molded product that is excellent in strength, rigidity and impact resistance, and also excellent in sound absorption, cushioning, heat insulation, sawing, nailing, etc. And to provide a laminate in which a layer made of an organic material, an inorganic material or the like is laminated on the reinforced resin molded body as a base material, and further, a production method for easily producing these using palm shell fibers It is an object of the present invention to provide a material for utilizing palm shell long fibers that can be used for ceiling materials, wall materials, floor materials, furniture, tatami floors, packing materials, pallet materials, etc. using these materials.

[0005]

Means for Solving the Problems As a result of repeated studies to sufficiently effectively utilize the properties such as strength of coconut shell fibers, the present inventors have found that coconut shell long fibers are arranged mainly in two dimensions at random.
A three-dimensional palm shell long-fiber mat in which fibers are randomly arranged in the thickness direction also penetrates from the bottom surface to the surface of the mat in the thickness direction perpendicular to the width direction and the longitudinal direction of the mat, and the bottom surface and the surface. In, a mat obtained by arranging a large number of palm shell filaments intimately entangled with other fibers on the bottom surface and the surface in a specific form at intervals in the width direction and the longitudinal direction, or this mat A three-dimensional palm shell long fiber structure mat reinforced resin molded product formed by using a mat having two or more laminated layers as a reinforcing material and using a thermosetting resin and / or a thermoplastic resin as a matrix, or this reinforced resin molded product We found that the problem can be solved by laminating other materials, and these reinforced resin moldings and laminates can be used for ceiling materials, wall materials, floor materials, furniture, tatami floors, packing materials, pallet materials, etc. And we have completed the present invention found to be suitable as materials.

The invention according to claim 1 of the present invention is mainly composed of fibers arranged in parallel and randomly intertwined with a plane having the Y axis in the width direction and the X axis in the longitudinal direction at right angles thereto. 3 more randomly entangled in the thickness direction
Dimensional palm shell filament mat Z perpendicular to the Y and X axes
Three-dimensional palm-shell long-fiber structure in which a large number of two or more palm-shell long fibers that penetrate axially from the bottom surface to the surface are arranged at intervals in the width direction and the longitudinal direction. A mat, wherein one end of the Z-axis fibers is intimately intertwined with another fiber at the bottom of the mat, and most of the other Z-axis fibers form a loop, This loop is folded back on the surface of the mat and intimately entangled with other fibers. A three-dimensional palm shell long fiber structure mat, or a mat in which two or more three-dimensional palm shell long fiber structure mats are laminated. Is used as a reinforcing material and is formed by using a thermosetting resin and / or a thermoplastic resin as a matrix.

The invention according to claim 2 of the present invention is characterized in that the fibers of the three-dimensional palm shell long fiber structure mat according to claim 1 are adhered and fixed using a binder. The three-dimensional palm shell long-fiber structure mat-reinforced resin molding described.

According to a third aspect of the present invention, the three-dimensional palm shell long fiber structure mat-reinforced resin molded body according to the first or second aspect is used as a base material, and an organic material made of another material and And / or at least one layer of inorganic material
It is a laminated body characterized by being laminated.

The invention of claim 4 of the present invention provides the following (1)
The method for producing a three-dimensional palm shell long fiber structure mat-reinforced resin molded product according to claim 1, comprising the steps (1) to (5). (1) 3 short lengths of palm shell long fibers from which short fibers and dust have been removed
Mainly fibers that are randomly entangled randomly and entangled in parallel in a plane consisting of the width direction and the longitudinal direction at right angles to the main surface, and the fibers extend in the thickness direction. The process of making a three-dimensional palm shell filament mat that is even more randomly entwined. (2) The obtained three-dimensional palm shell long fiber mat is needle-punched, and at least one of the fibers randomly entwined in parallel with the bottom surface of the mat is hung on a needle to form a loop, and the surface of this mat To the surface of the mat at a predetermined distance from the surface of the mat, and repeatedly pulling the loop away from the needle. A process of making a three-dimensional palm-shell long-fiber structure mat by arranging a large number of palm-shell long-fibers at intervals in the width direction and the longitudinal direction of the mat. (3) The obtained three-dimensional palm shell long fiber structure mat is compressed, and the loop pulled up to a position separated by a predetermined distance from the surface of the mat is folded back on the surface of the mat,
The process of intimately intertwining with other fibers on the surface of this mat. (4) A step of impregnating the obtained three-dimensional palm shell long fiber structure mat with a thermosetting resin and / or a thermoplastic resin, and drying if necessary. (5) One or two mats obtained in the process of (4)
A step of stacking one or more layers, heating, pressurizing and molding, and then cooling.

The invention of claim 5 of the present invention provides the following (1)
The method for producing a three-dimensional palm shell long fiber structure mat-reinforced resin molded product according to claim 2, which comprises steps (6) to (6). (1) 3 short lengths of palm shell long fibers from which short fibers and dust have been removed
Mainly fibers that are randomly entangled randomly and entangled in parallel in a plane consisting of the width direction and the longitudinal direction at right angles to the main surface, and the fibers extend in the thickness direction. The process of making a three-dimensional palm shell filament mat that is even more randomly entwined. (2) The obtained three-dimensional palm shell long fiber mat is needle-punched, and at least one of the fibers randomly entwined in parallel with the bottom surface of the mat is hung on a needle to form a loop, and the surface of this mat To the surface of the mat at a predetermined distance from the surface of the mat, and repeatedly pulling the loop away from the needle. A process of making a three-dimensional palm-shell long-fiber structure mat by arranging a large number of palm-shell long-fibers at intervals in the width direction and the longitudinal direction of the mat. (3) The obtained three-dimensional palm shell long fiber structure mat is compressed, and the loop pulled up to a position separated by a predetermined distance from the surface of the mat is folded back on the surface of the mat,
The process of intimately intertwining with other fibers on the surface of this mat. (4) A step of applying or adhering a binder to the three-dimensional palm shell long fiber structure mat and then drying and adhering and fixing the fibers with the binder. (5) A step of impregnating this three-dimensional palm shell long fiber structure mat with a thermosetting resin and / or a thermoplastic resin, and drying if necessary. (6) One or two mats obtained in the process of (5)
A step of stacking one or more layers, heating, pressurizing and molding, and then cooling.

According to a sixth aspect of the present invention, the three-dimensional palm shell long fiber structure mat-reinforced resin molded body according to the first or second aspect is used as a base material, with or without an adhesive. And / or organic materials made of other materials as the base material and /
Alternatively, the method for producing a laminated body according to claim 3, wherein at least one layer made of an inorganic material is laminated.

The invention according to claim 7 of the present invention comprises the three-dimensional palm shell long fiber structure mat-reinforced resin molded product according to claim 1 or 2, or the laminate according to claim 3. It is a material using palm shell long fibers characterized by.

The invention according to claim 8 of the present invention is used as a ceiling material, a wall material, a floor material, furniture, a tatami floor, a packing material, and a pallet material in the material using palm shell long fibers according to claim 7. Is characterized by. Hereinafter, the contents of the present invention will be described in detail.

[0014]

BEST MODE FOR CARRYING OUT THE INVENTION Palm shell fiber is a fiber obtained from a palm husk (outer skin portion), and the husk usually comprises long fibers, short fibers and Coyer dust. The palm shell fibers used in the present invention are long fibers from which short fibers and Coyer dust have been removed. In order to obtain this long fiber, first, palm fruit is separated into husks and seeds, short fibers and Coyer dust are removed, and long fibers are collected to obtain palm shell long fibers.

It is to be noted that, as a palm fruit which is a raw material of palm long fiber, one having an excellent outer skin portion of fiber is suitable, and among palm plants, coco palm (Cocos nucifera) is suitable.
(Cocos nucifera), Cocos butyrac
ea) etc.] is preferred.

The obtained coconut long fibers are generally brown or dark brown and have a texture of coarse hair, and the fiber length is about 5
-30 cm, preferably about 10-30 cm, more preferably about 15-30 cm, diameter about 0.03-0.3 m.
m, preferably about 0.1 to 0.3 cm, more preferably about 0.2 to 0.3 mm. If the fiber length is less than about 5 cm, it is difficult to obtain the strength, rigidity and peel strength of the mat,
It is difficult to practically obtain a fiber having a fiber length of more than about 30 cm. If the diameter of the fiber is less than about 0.03 mm, it is difficult to obtain the strength, rigidity, peel strength and the like of the mat, and it is difficult to practically obtain the fiber having a diameter of more than about 0.3 mm.

Next, using this palm long filament, the reinforcing fiber is conceptually shown in FIG. 1 (a) and FIG. 1 (b) showing an enlarged portion A of FIG. 1 (a) by the process shown in FIG. An example of producing the three-dimensional palm shell long fiber structure mat-reinforced resin molded product [Product (I)] of the present invention showing the fiber structure and the resin M of the matrix will be described. First, as shown in FIG. 5, an aggregate of palm shell long fibers 1 is three-dimensionally randomly entangled by a fiber opening machine 2 to be spread in a plane, and the width direction (X axis).
And mainly the fibers that are randomly entangled and arranged in parallel to a surface consisting of a longitudinal direction (Y axis) perpendicular to the
In addition, a three-dimensional palm shell long fiber mat a in which the fibers are further entangled randomly also in the thickness direction (Z axis) is prepared. The fiber structure of this three-dimensional palm shell long fiber mat a is conceptually shown in FIG. This step may be carried out by loosening by hand, or may be appropriately entangled using a machine as described above. It should be noted that synthetic fibers such as polyamide, polyester, and polyolefin, and other natural fibers such as cotton and hemp may be appropriately mixed in this step without departing from the scope of the present invention.

Next, as shown in FIGS. 6A to 6D, the obtained three-dimensional palm shell long fiber mat a is needle punched by the needle punching machine 3. In FIG. 6A, before inserting the needle 13 from above in the thickness direction (Z axis), which is substantially perpendicular to the plane consisting of the width direction (X axis) and the longitudinal direction (Y axis) perpendicular thereto. Indicates the state of. Figure 6 (b)
The state in which the needle 13 is inserted from above the mat a is shown in FIG. As shown in FIG. 6C, at least one fiber 10 which is randomly entangled in parallel with the bottom surface of the mat a is hooked on the needle 13 to form a loop 12 in a direction substantially perpendicular to the surface of the mat a (Z The shaft is pulled up to a position separated from the surface of the mat a by a predetermined distance h. The fibers 10 are randomly entangled with other fibers 14 on the bottom surface of the mat. The number of fibers 10 to be hung on the needles 13 and the intervals between the multiple needles vary depending on the intended use of the mat of the product, but in order to improve properties such as strength, rigidity and peel strength, the number is large and the intervals are close. Is preferred. The type, shape, size, material, etc. of the needle 13 are not particularly limited.

The pulling-up distance h varies depending on the thickness of the mat a, the length of the palm shell filaments, etc., but a larger pulling-up distance is preferable because the loop entanglement on the mat surface can be improved. However, if the pulling distance is too large, all the fibers are pulled out from the bottom surface of the mat, which is not preferable. Therefore, it is preferable to determine the pulling distance so that the entanglement of the fibers on the bottom surface of the mat is sufficiently left and the entanglement of the loop on the mat surface is sufficient.

FIG. 6D shows a state in which the mat 12 is advanced to separate the loop 12 from the needle 13 and the needle 13 is in a predetermined position for the next operation. By repeating the above operation, a large number of two or more coconut shell filaments 11 penetrating from the bottom surface to the surface of the mat are arranged at intervals in the width direction and the longitudinal direction of the mat. Three-dimensional palm shell filament structure mat b
make. As described above, it is preferable that the distance between the needles and the number of the long fibers 11 are determined according to the desired characteristics such as strength, rigidity and peel strength of the mat. In general, the narrower the spacing and the larger the number, the better the characteristics such as strength, rigidity and peel strength.

The three-dimensional palm shell long fiber structure mat b thus obtained is compressed by a roll 4 or the like and pulled up to a position separated from the surface of the mat by a predetermined distance h.
2 is folded back on the surface of this mat and intimately entangled with the other fibers 15 on the surface of this mat to produce the three-dimensional palm shell long fiber structure mat c of the present invention.

In the impregnation step 5, the three-dimensional palm shell long fiber structure mat c is impregnated with a thermosetting resin such as an epoxy resin type thermosetting resin or a thermoplastic resin such as ABS.
The prepreg mat is manufactured by heating in the drying step 6. In the press molding step 7, one or more prepreg mats are laminated, heated, pressed and molded, and then cooled to manufacture the product (I).

The resin to be impregnated may be blended with a pigment, an antioxidant, a mildew proofing agent, a repellent agent, an antibacterial agent, a filler and the like. Also, palm shell short fibers, other natural fibers, synthetic fibers and the like, which are by-produced during the production of palm shell long fibers, may be mixed.

The method of impregnating the mat c with a resin is not particularly limited. For example, any of a spray method, a dipping method, a pultrusion method, a melt extrusion method and the like may be used. The amount of resin to be impregnated is also not particularly limited. When the amount of resin impregnated is small, a lightweight, porous product with a small bulk density is obtained, and when the amount of impregnated resin is large, a product with a high bulk density, strength, and rigidity is obtained. It is preferable to appropriately determine it according to the purpose of use.

In the present invention, the matrix resin may be a thermosetting resin, a thermoplastic resin, or a combination thereof, such as olefin resin such as polyethylene, polypropylene, ethylene-propylene copolymer, polybutene, poly Vinyl resins such as vinyl chloride, polyvinyl acetate, ethylene / vinyl acetate copolymer, polystyrene, styrene resins such as ABS, polyamide resins, polyester resins, polycarbonate resins, acrylic resins, polyurethane resins, phenol Examples thereof include resin based resins, urea based resins, melamine based resins, unsaturated polyester based resins, and epoxy based resins.

Next, by using the above-mentioned long palm fibers, the reinforcing fiber is conceptually shown in FIG. 2 (B) which is an enlarged view of the portion B of FIG. 2 (A) and FIG. 2 (A) by the process shown in FIG. An example of producing another three-dimensional palm shell long fiber structure mat-reinforced resin molded product [Product (II)] of the present invention showing the fiber structure and the resin M of the matrix will be described. First, as shown in FIG. 7, in the same manner as described above, an aggregate of palm shell long fibers 1 is three-dimensionally randomly entangled by a fiber opening machine 2 to be spread in a plane, and the width direction (X axis), On the other hand, the fiber is mainly composed of fibers that are randomly entangled in parallel to a plane that is perpendicular to the longitudinal direction (Y axis), and the fibers are further entangled randomly in the thickness direction (Z axis). A long fiber mat a is made.

Next obtained three-dimensional palm shell filament mat a
Are needle punched by the needle punch machine 3 in the same manner as described above. The obtained three-dimensional palm shell long fiber structure mat b is compressed by a roll 4 or the like in the same manner as described above, and the loop 12 pulled up to a position separated from the surface of the mat by a predetermined distance h is used as the mat. The surface of the mat is closely folded and entangled with other fibers 15 on the surface of the mat to form the three-dimensional palm shell long fiber structure mat c of the present invention.

Next, in the binder coating step 8, this mat c
The binder 9 is applied to or adhered to by a spray method, an impregnation method, or the like, and then dried by a dryer 16 to bond and fix the fibers. The mat obtained by treating with the binder 9 can be used in a bulky state as it is, or can be used in a more dense form by being compressed by a roll or a press 17. The mat d thus produced is cut into a predetermined size by the sheeting machine 18. The bulk density of the mat d is not particularly limited. The bulk density is, for example, specifically in the range of 0.01 to 0.4 g / cm ³ ,
Preferably, the range of 0.03 to 0.3 g / cm ³ can be mentioned.

The binder for adhering and fixing the fibers to each other is not particularly limited. Specific examples of the binder that can be used in the present invention include natural rubber latex, or synthetic rubber latex such as styrene-butadiene latex and acrylonitrile-butadiene latex, or polyacrylic acid emulsion, polyvinyl acetate emulsion, polyvinyl chloride emulsion, ethylene. -Vinyl acetate-vinyl chloride terpolymer emulsion such as thermoplastic resin emulsion, epoxy resin emulsion, urethane resin emulsion, thermosetting resin emulsion such as urea or melamine resin emulsion, or solutions thereof be able to. Binder type, usage, etc.
It is preferable to appropriately select and use according to the characteristics.

In the impregnation step 5, the three-dimensional palm shell long fiber structure mat d is impregnated with a thermosetting resin such as an epoxy resin thermosetting resin or a thermoplastic resin such as ABS. The prepreg mat is manufactured by heating in the drying step 6. In the press molding step 7, one or more prepreg mats are laminated, heated, pressed and molded, and then cooled to manufacture the product (II).

In the present invention, a plurality of the three-dimensional palm shell long fiber structure mats c or the three-dimensional palm shell long fiber structure mats d are laminated to form a laminated three-dimensional palm shell long fiber. The structure mat is used to impregnate the resin with the 3 of the present invention.
A dimensional palm shell long-fiber structure mat-reinforced resin molded product can be produced. When the mats are laminated, the laminated mats are needle punched in the same manner as described above to strengthen the interlayers of the laminated three-dimensional palm shell long fiber structure mats as needed, and the width between the layers of the mats is increased. Arrange a large number of palm shell filaments 11 at intervals in the longitudinal and longitudinal directions,
Alternatively, instead of the needle punching method,
It is preferable to sew the layers with a gap in the width direction and the longitudinal direction of the mats laminated by the bonding method. Further, the mat thus obtained is compressed, and the loop pulled up to a position separated from the surface of the mat by a predetermined distance is folded back to the surface of the mat and tightly attached to other fibers on the surface of the mat. It is preferable to entangle with each other.

FIG. 3 shows a three-dimensional palm shell long fiber structure mat c or a three-dimensional palm shell long fiber structure mat in which a plurality of (three) three-dimensional palm shell long fiber structure mats d are laminated. A diagram conceptually showing the fiber structure of the reinforcing fibers and the resin M of the matrix of the three-dimensional palm shell long fiber structure mat reinforced resin molded body 21 which is used as a reinforcing material and is impregnated with a resin in the same manner as described above. Is. Note that the number of layers to be laminated, the combination order of the three-dimensional palm shell long fiber structure mat c and the three-dimensional palm shell long fiber structure mat d, the number of each, and the like are not particularly limited. In FIG. 3, the same reference numerals as those in FIGS. 1 and 2 indicate the same parts.

The three-dimensional palm shell long fiber structure mat-reinforced resin molded product of the present invention can be effectively used as it is as a material for utilizing palm shell long fibers. For example, these are peel resistance, strength,
In addition to being excellent in rigidity, etc., it is also excellent in sound absorption, cushioning, cushioning, vibration damping, heat insulation, cutting, nailing, etc. It can be suitably used for applications such as ceiling materials, wall materials, and floor materials for airplanes, furniture, tatami floors, packing materials, pallet materials, and the like.

Using the three-dimensional palm shell long fiber structure mat-reinforced resin molded product of the present invention as a substrate, at least one layer made of an organic material and / or an inorganic material made of another material, and an adhesive are used. Alternatively, it can be laminated without using an adhesive to form a laminated body.

Examples of the organic material include natural products and synthetic products such as plastics, flame-retardant plastics,
Examples of the inorganic material such as paper, wood, leather, cloth, woven cloth, and non-woven cloth include natural products or synthetic products such as metal, glass, and ceramics. Examples of these forms include films, sheets, and plates. Examples thereof include corrugated materials, corrugated materials, foams, powders, fibers, and honeycombs. By laminating layers made of these materials, there is the effect that the surface characteristics can be changed, such as making the surface beautiful and making it difficult to slip, and it also has sound absorbing, cushioning, cushioning, and vibration damping properties. , Heat insulation, moisture proof,
It can be used as a material for utilizing palm shell long fibers with improved flame retardancy, strength and rigidity. This material using palm shell long fibers can be used for various purposes. For example, by utilizing the above characteristics, it can be more suitably used for applications such as ceiling materials, wall materials, and floor materials for interiors, vehicles, ships, airplanes, and furniture, tatami floors, packing materials, pallet materials, etc. You can FIG.
FIG. 3 is a perspective view illustrating the structure of the laminate of the present invention. This laminate has a three-dimensional palm shell long fiber structure mat reinforced resin molded body 22 of the present invention as a base material, and a wood layer 20 on the surface thereof.
Are laminated via an adhesive 19.

[0036]

According to the present invention, a three-dimensional palm shell filament mat using palm shell filaments penetrates from the bottom surface to the surface in the thickness direction perpendicular to the width direction and the longitudinal direction, and the bottom surface. Three-dimensional palm-shell filaments in which a large number of palm-shell filaments intimately entwined with other fibers on the bottom and the surface in a specific form are densely arranged at intervals in the width direction and the longitudinal direction The matrix resin is reinforced by using the structure mat as a reinforcing material, so that the three-dimensional palm shell length with three-dimensionally improved properties such as strength, rigidity and peeling strength and excellent nailability and machinability A fiber structure mat-reinforced resin molded product can be provided.

Fibers were bonded and fixed with a binder. 3
When the dimension palm shell long fiber structure mat is used as a reinforcing material, properties such as strength, rigidity and peeling strength of the reinforced resin molding can be further improved. Flame retardants, pigments for resins and binders,
Addition of fragrances, mildew-proofing agents, anti-dandruff agents, anti-bacterial agents, etc. to give flame retardancy, coloring, and incense to a three-dimensional palm long fiber structure mat reinforced resin molded product. Such characteristics can be added.

If these three-dimensional palm shell long fiber structure mats are laminated and preferably the three-dimensional palm shell long fiber structure mat further reinforced between layers is used as a reinforcing material,
A three-dimensional palm shell long fiber structure mat-reinforced resin molded product having a thick thickness and three-dimensionally improved properties such as strength, rigidity, and peel strength can be provided.

These three-dimensional palm shell long fiber structure mat reinforced resin moldings have sound absorbing properties, cushioning properties, cushioning properties, vibration damping properties, heat insulating properties, moisture proof properties, flame retardancy, strength, rigidity and impact resistance. ,
It can be used as a material using palm shell long fibers, which has excellent nailing and cutting properties.

The surface of the three-dimensional palm shell long fiber structure mat-reinforced resin molding of the present invention is used as a base material and a layer made of an organic material or an inorganic material is laminated on the base material to make the surface beautiful. It has the effect that it can have changes in surface characteristics, such as making it difficult to slip, and it also has sound absorption, cushioning, cushioning, vibration damping, heat insulation,
Since moisture resistance, flame retardancy, strength, rigidity, impact resistance, etc. are improved, it can be used as a material using palm shell long fibers by utilizing these characteristics.

These three-dimensional palm shell long fiber structure mat reinforced resin moldings and laminates are used, for example, as ceiling materials, wall materials, floor materials, packing materials, pallet materials for interiors, vehicles, ships, airplanes, etc. It can be suitably used for applications such as, and applications such as furniture and tatami floors. Examples of the packaging material include an example in which a wood box, a wooden box, a wooden frame, etc., which are conventionally made of wood or plywood, are replaced by the palm shell long fiber material of the present invention. it can. As an example of the pallet material, for example, conventionally,
An example in which the material of the pallet made of wood, metal such as steel or aluminum, or plastic is replaced with the material using palm shell long fibers of the present invention can be given.

By the production method of the present invention, a product having the above-mentioned excellent effects can be easily provided by using palm shell fiber.

[0043]

EXAMPLES The present invention will be specifically described below with reference to examples, but the present invention is not limited to these examples. (Example 1) Urea resin was used for the mat d (thickness 20 m
m, the distance between needle punch punches was about 1 cm, and an epoxy resin was used as a binder. ) Is impregnated with about 5% by weight, heated and dried, three prepreg mats are laminated, heated at 170 ° C. for 10 minutes, compressed and molded, then cooled to room temperature and smoothed. A synthetic wood-like board product having a surface (bulk density of about 0.69 g / cm ³ , thickness of about 5 mm) (three-dimensional palm shell long fiber structure mat-reinforced resin molded product of the present invention) was produced. The bending strength of this product,
Table 1 shows the results of a test for measuring the Young's modulus, the peel strength, and the expansion coefficient of the thickness when immersed in water at 20 ° C. for 2 hours and 24 hours to absorb water. Thickness 1 for comparison
The results of the same test performed on a 2 mm particle board are also shown.

[0044]

[Table 1]

From Table 1, the three-dimensional palm shell long fiber structure mat-reinforced resin molding of the present invention has excellent bending strength, Young's modulus,
It can be seen that it has characteristics such as peel strength. The synthetic wood-like product of the present invention was easily cut with a normal saw and had a clean cut. Further, when a nail is struck on the synthetic wood-like product of the present invention, the nail is squeezed well, and there is no problem that the product is cracked even if the nail is struck on the end of the product, and the nail can be neatly struck. It was In addition, it was possible to drive nails neatly using an automatic nailing machine.

[0046]

The three-dimensional palm shell long fiber structure mat reinforced resin molded product of the present invention is a right angle to the width direction and the longitudinal direction of a three-dimensional palm shell long fiber mat using palm shell long fibers. The coconut long filaments that penetrate the mat from the bottom surface to the surface in a uniform thickness direction and are intimately entwined with other fibers on the bottom surface and the surface in a specific form in the width direction and the longitudinal direction. Since the resin is reinforced by using the three-dimensional palm shell long fiber structure mats densely arranged at intervals as a reinforcing material, it is possible to three-dimensionally improve the properties such as strength, rigidity and peel strength. .

Fibers were bonded and fixed with a binder 3
Another three-dimensional palm shell long fiber structure mat reinforced resin molding of the present invention using the three-dimensional palm shell long fiber structure mat as a reinforcing material has three-dimensional characteristics such as strength, rigidity and peel strength. Can be further improved. A three-dimensional palm shell long fiber structure of the present invention by blending a flame retardant, a pigment, a fragrance, an antifungal agent, an antifungal agent, an antibacterial agent, a filler, a palm shell short fiber, etc. in a resin or binder. It is also possible to impart various properties such as flame retardancy to the body mat reinforced resin molded body.

Another 3 of the present invention wherein a three-dimensional palm shell long fiber structure mat is laminated and preferably a further three-dimensional palm shell long fiber structure mat is used as a reinforcing material.
The three-dimensional palm shell long fiber structure mat-reinforced resin molded product has a large thickness and can further improve three-dimensionally such properties as strength, rigidity and peel strength.

These three-dimensional palm shell long fiber structure mat reinforced resin moldings of the present invention are sound absorbing, cushioning, buffering, vibration damping, heat insulating, strength, rigidity, flame retardant, nailing. ,
It can be used as a material that uses palm shell long fibers with excellent machinability.

The surface of the three-dimensional palm shell long fiber structure mat-reinforced resin molded product of the present invention can be made beautiful by using it as a base material and laminating a layer made of an organic material or an inorganic material. , It has the effect of making it possible to have changes in the surface characteristics such as making it difficult to slip, sound absorption, cushioning, cushioning, vibration insulation, heat insulation, moisture resistance,
Since flame retardancy, strength, rigidity, etc. are improved, it can be used as a material utilizing palm shell long fibers by utilizing these characteristics.

These materials for utilizing palm shell long fibers composed of the three-dimensional palm shell long fiber structure mat-reinforced resin molded product of the present invention and the laminate of the present invention can be used, for example, in indoors, vehicles, ships and airplanes. It can be suitably used for applications such as ceiling materials, wall materials and floor materials, and applications such as furniture, tatami floors, packing materials and pallet materials. These three-dimensional palm shell long fiber structure mat-reinforced resin molded products and laminates can be easily manufactured by using the palm shell fibers by the manufacturing method of the present invention.

The present invention is a substitute for conventional wood, plywood, etc., which has been a problem as environmental destruction due to deforestation.
By effectively utilizing coconut shell fiber, which had a low utility value up to now, it is possible to easily provide products that are kind to the earth and have the above-mentioned excellent effects, and thus have a high industrial utility value. At the same time, it is extremely meaningful in terms of environmental protection issues.

[Brief description of drawings]

FIG. 1A is a schematic diagram showing a fiber structure of a reinforcing fiber and a resin of a matrix of a three-dimensional palm shell long fiber structure mat-reinforced resin molded product of the present invention. (B) is an enlarged explanatory view of a portion A of (A).

FIG. 2 (a) is a schematic diagram showing the fiber structure of the reinforcing fibers and the resin of the matrix of the other three-dimensional palm shell long fiber structure mat-reinforced resin molded product of the present invention. (B) is an enlarged explanatory view of a portion B of (A).

FIG. 3 shows the fiber structure and matrix of the reinforcing fibers of another three-dimensional palm shell long fiber structure mat reinforced resin molding of the present invention using the laminated three-dimensional palm shell long fiber structure mat as a reinforcing material. It is an enthusiasm figure which shows resin.

FIG. 4 is a perspective view illustrating a structure of a laminate of the present invention in which a layer of another material is laminated on a three-dimensional palm shell long fiber structure mat-reinforced resin molded body.

FIG. 5 is an explanatory diagram showing a manufacturing process of the three-dimensional palm shell long fiber structure mat-reinforced resin molded product of the present invention shown in FIG. 1.

6A to 6D are explanatory views showing the operation process of the needle punch.

FIG. 7 is an explanatory view showing a manufacturing process of another three-dimensional palm shell long fiber structure mat-reinforced resin molded product of the present invention shown in FIG.

[Explanation of symbols]

1, 11 Palm shell long fiber 2 Fiber opening machine 3 Needle punch machine 4 Roll 5 Impregnation step 6 Drying step 7 Press molding step 8 Binder application step 9 Binder 10, 14, 15 Fiber 12 Loop 13 Needle 16 Dryer 17 Press 18 sheeting machine 19 adhesive 20 wood 21, 22 three-dimensional palm shell long fiber structure mat reinforced resin molding

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification code Internal reference number FI Technical display location B32B 9/02 B32B 9/02 E04C 2/24 E04C 2/24 R // B29K 105: 06 B29L 9 : 00 (72) Inventor Eiji Sato 1-1-1 Hatagaya, Shibuya-ku, Tokyo Within CFB Japan Co., Ltd. (72) Inventor Kaoru Tsujimura 1-1-1 Hatagaya, Shibuya-ku, Tokyo C FB Japan (72) Inventor Mamoru Kobayashi 1-1-1 Hatagaya, Shibuya-ku, Tokyo CFB Japan Co., Ltd.

Claims (8)

[Claims] 1. A fiber mainly composed of fibers arranged randomly intertwined in parallel with a plane having a width direction as a Y axis and a longitudinal direction perpendicular to the Y axis as an axis, and the fibers are further randomly distributed in a thickness direction. Two or more coconut long filaments that penetrate the bottom surface of the intertwined three-dimensional long coconut filament mat in the Z-axis direction perpendicular to the Y-axis and the X-axis are And a three-dimensional palm-shell long-fiber structure mat having a large number of fibers arranged at intervals in the longitudinal direction, wherein one end of the fibers in the Z-axis direction is intimately entangled with other fibers on the bottom surface of the mat. And most of the other ends of the fibers in the Z-axis direction form loops, which loops are folded back on the surface of the mat and intimately entangled with other fibers. Structure mat or A three-dimensional palm shell, which is formed by using a mat in which two or more three-dimensional palm shell long fiber structure mats are laminated as a reinforcing material and using a thermosetting resin and / or a thermoplastic resin as a matrix. Long fiber structure mat reinforced resin molding. 2. The three-dimensional palm shell length according to claim 1, wherein the fibers of the three-dimensional palm shell long fiber structure mat according to claim 1 are bonded and fixed using a binder. Fiber structure mat reinforced resin molding. 3. A three-dimensional palm shell long fiber structure mat reinforced resin molded product according to claim 1 or 2 is used as a base material,
At least one layer made of an organic material and / or an inorganic material made of another material is laminated thereon. 4. The method for producing a three-dimensional palm shell long fiber structure mat-reinforced resin molded product according to claim 1, comprising the following steps (1) to (5). (1) 3 short lengths of palm shell long fibers from which short fibers and dust have been removed
Mainly fibers that are randomly entangled randomly and entangled in parallel in a plane consisting of the width direction and the longitudinal direction at right angles to the main surface, and the fibers extend in the thickness direction. The process of making a three-dimensional palm shell filament mat that is even more randomly entwined. (2) The obtained three-dimensional palm shell long fiber mat is needle-punched, and at least one of the fibers randomly entwined in parallel with the bottom surface of the mat is hung on a needle to form a loop, and the surface of this mat To the surface of the mat at a predetermined distance from the surface of the mat, and repeatedly pulling the loop away from the needle. A process of making a three-dimensional palm-shell long-fiber structure mat by arranging a large number of palm-shell long-fibers at intervals in the width direction and the longitudinal direction of the mat. (3) The obtained three-dimensional palm shell long fiber structure mat is compressed, and the loop pulled up to a position separated by a predetermined distance from the surface of the mat is folded back on the surface of the mat,
The process of intimately intertwining with other fibers on the surface of this mat. (4) A step of impregnating the obtained three-dimensional palm shell long fiber structure mat with a thermosetting resin and / or a thermoplastic resin, and drying if necessary. (5) One or two mats obtained in the process of (4)
A step of stacking one or more layers, heating, pressurizing and molding, and then cooling. 5. The method for producing a three-dimensional palm shell long fiber structure mat-reinforced resin molded product according to claim 2, which comprises the following steps (1) to (6). (1) 3 short lengths of palm shell long fibers from which short fibers and dust have been removed
Mainly fibers that are randomly entangled randomly and entangled in parallel in a plane consisting of the width direction and the longitudinal direction at right angles to the main surface, and the fibers extend in the thickness direction. The process of making a three-dimensional palm shell filament mat that is even more randomly entwined. (2) The obtained three-dimensional palm shell long fiber mat is needle-punched, and at least one of the fibers randomly entwined in parallel with the bottom surface of the mat is hung on a needle to form a loop, and the surface of this mat To the surface of the mat at a predetermined distance from the surface of the mat, and repeatedly pulling the loop away from the needle. A process of making a three-dimensional palm-shell long-fiber structure mat by arranging a large number of palm-shell long-fibers at intervals in the width direction and the longitudinal direction of the mat. (3) The obtained three-dimensional palm shell long fiber structure mat is compressed, and the loop pulled up to a position separated by a predetermined distance from the surface of the mat is folded back on the surface of the mat,
The process of intimately intertwining with other fibers on the surface of this mat. (4) A step of applying or adhering a binder to the three-dimensional palm shell long fiber structure mat and then drying and adhering and fixing the fibers with the binder. (5) A step of impregnating this three-dimensional palm shell long fiber structure mat with a thermosetting resin and / or a thermoplastic resin, and drying if necessary. (6) One or two mats obtained in the process of (5)
A step of stacking one or more layers, heating, pressurizing and molding, and then cooling. 6. A three-dimensional palm shell long fiber structure mat reinforced resin molded product according to claim 1 or 2 is used as a base material, and another material is used for the base material with or without an adhesive. 4. At least one layer made of an organic material and / or an inorganic material is laminated.
The method for producing a laminate according to the above. 7. A palm shell length comprising the three-dimensional palm shell long fiber structure mat-reinforced resin molded product according to claim 1 or 2, or the laminated body according to claim 3. Fiber utilization material. 8. The material using palm shell long fibers according to claim 7, which is used as a ceiling material, a wall material, a floor material, furniture, a tatami mat, a packing material, and a pallet material.